Methods of forming an asphalt shingle waste powder from asphalt shingle waste

ABSTRACT

Non-limiting embodiments of the present disclosure relate to a method comprising: obtaining asphalt shingle waste (ASW) and performing grinding, screening, and separating steps on the ASW. In some embodiments, granules are removed from the ASW. In some embodiments, the method transforms ASW into ASW powder. In some embodiments, the ASW powder is formed into a plurality of briquettes. In some embodiments, at least one of: the ASW powder, the plurality of briquettes, or any combination thereof is fed into a mixing process that results in an ASW powder filled coating.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/951,756 filed Nov. 18, 2020, which is a continuation of U.S. patentapplication Ser. No. 16/883,503 filed May 26, 2020, now U.S. Pat. No.10,858,790, which is a continuation of U.S. patent application Ser. No.16/789,219 filed Feb. 12, 2020, now U.S. Pat. No. 10,683,620, whichclaims priority to U.S. Provisional Application No. 62/904,476 filedSep. 23, 2019, and to U.S. Provisional Application No. 62/912,411 filedOct. 8, 2019, all of which are incorporated herein by reference in theirrespective entirety for all purposes.

FIELD

In some embodiments, the present disclosure relates to methods offorming asphalt shingle waste powder from asphalt shingle waste.

In some embodiments, the field of the present disclosure relates to theformation of filled coatings from asphalt shingle waste (ASW) or asphaltcontaining (AC) powders.

BACKGROUND

Approximately 11 million tons of asphalt shingle waste (ASW) aregenerated in the U.S. each year. ASW can take hundreds of years todecompose in a landfill. Accordingly, ASW presents a major environmentalproblem. Improved methods of processing ASW are needed.

SUMMARY

Covered embodiments are defined by the claims, not this summary. Thissummary is a high-level overview of various aspects and introduces someof the concepts that are further described in the Detailed Descriptionsection below. This summary is not intended to identify key or essentialfeatures of the claimed subject matter, nor is it intended to be used inisolation to determine the scope of the claimed subject matter. Thesubject matter should be understood by reference to appropriate portionsof the entire specification, any or all drawings, and each claim.

Some embodiments of the present disclose relate to a method comprising:obtaining asphalt shingle waste (ASW), wherein the ASW comprises:asphalt, limestone, granules, and impurities; grinding the ASW to formground ASW; screening the ground ASW with a rotary screener, wherein thescreening of the ground ASW with the rotary screener results in: a firstset of ASW particles, wherein the first set of ASW particles has anaverage particle size of 425 microns to 6350 microns, and a second setof ASW particles, wherein the second set of ASW particles has an averageparticle size of 2 microns to 425 microns; removing at least some of thegranules from at least one of the first set of ASW particles, the secondset of ASW particles, or a combination thereof with a granule liberator;grinding the first set of ASW particles, wherein the grinding of thefirst set of ASW particles results in a third set of ASW particles,wherein the third set of ASW particles has an average particle size of 2microns to 425 microns; separating the second and third sets of ASWparticles using an air separator, wherein the separating using the airseparator results in: a fourth set of ASW particles, wherein the fourthset of ASW particles have an average particle size of 250 microns to 450microns; and a fifth set of ASW particles, wherein the fifth set of ASWparticles has an average particle size of 2 microns to 250 microns;grinding the fourth set of ASW particles; wherein the grinding of thefourth set of ASW particles results in a sixth set of ASW particles,wherein the sixth set of ASW particles have an average particle size of2 microns to 250 microns; wherein each of the fifth set of ASW particlesand the sixth set of ASW particles is an ASW powder having the followingcomposition: 5 wt % to 40 wt % asphalt based on a total weight of theASW powder, and 60 wt % to 95 wt % of limestone, granules, andimpurities based on the total weight of the ASW powder, wherein themethod does not comprise a wet extraction step.

Some embodiments of the present disclose relate to a method comprising:obtaining asphalt shingle waste (ASW), wherein the ASW comprises:asphalt, limestone, granules, and impurities; grinding the ASW to formground ASW; screening the ground ASW with a rotary screener, wherein thescreening of the ground ASW with the rotary screener results in: a firstset of ASW particles, wherein the first set of ASW particles has anaverage particle size of 425 microns to 6350 microns, and a second setof ASW particles, wherein the second set of ASW particles has an averageparticle size of 2 microns to 425 microns; removing at least some of thegranules from at least one of the first set of ASW particles, the secondset of ASW particles, or a combination thereof with a granule liberator;grinding the first set of ASW particles, wherein the grinding of thefirst set of ASW particles results in a third set of ASW particles,wherein the third set of ASW particles has an average particle size of 2microns to 425 microns; separating the second and third sets of ASWparticles using an air separator, wherein the separating using the airseparator results in: a fourth set of ASW particles, wherein the fourthset of ASW particles have an average particle size of 150 microns to 450microns; and a fifth set of ASW particles, wherein the fifth set of ASWparticles has an average particle size of 2 microns to 150 microns;grinding the fourth set of ASW particles; wherein the grinding of thefourth set of ASW particles results in a sixth set of ASW particles,wherein the sixth set of ASW particles has an average particle size of 2microns to 150 microns; wherein each of the fifth set of ASW particlesand the sixth set of ASW particles is an ASW powder having the followingcomposition: 5 wt % to 40 wt % asphalt based on a total weight of theASW powder, and 60 wt % to 95 wt % of limestone, granules, andimpurities based on the total weight of the ASW powder, wherein themethod does not comprise a wet extraction step.

In some embodiments, the rotary screener is a trommel screener.

In some embodiments, the method does not comprise a grinding step afterthe step of grinding the fourth set of ASW particles.

In some embodiments, the method does not comprise any grinding stepsother than the steps of: grinding the ASW, grinding the first set of ASWparticles, and grinding the fourth set of ASW particles.

In some embodiments, the impurities comprise least one of: fiberglassmat sand, fines, marker paint, sealant, one or more adhesives, tape,plastic debris, paper debris, soil, woods, nails, or any combinationthereof.

In some embodiments, the method does not comprise any steps of screeningwith a vibratory screener.

In some embodiments, the method does not comprise any steps of screeningwith a screening device that comprises at least one ball tray.

In some embodiments, the method does not comprise any steps of screeningwith a sizing shaker.

In some embodiments, the method does not comprise a screening step afterthe step of separating the second and third sets of ASW particles usingthe air separator.

In some embodiments, the second and third sets of ASW particles arecombined prior to the step of separating the second and third sets ofASW particles using the air separator.

In some embodiments, the fifth set of ASW particles and the sixth set ofASW particles are combined to form the ASW powder.

In some embodiments, the method further comprises forming the ASW powderinto a plurality of briquettes.

In some embodiments, forming the ASW powder into the plurality ofbriquettes comprises adding limestone powder to the ASW powder.

In some embodiments, forming the ASW powder into the plurality ofbriquettes comprises compressing the ASW powder at a pressure sufficientto form the plurality of briquettes.

In some embodiments, the pressure sufficient to form the plurality ofbriquettes ranges from 200 psi to 20,000 psi.

In some embodiments, each briquette of the plurality of briquettes is anoblate spheroid.

In some embodiments, each briquette of the plurality of briquettes has afirst diameter and a second diameter, wherein at least one of: the firstdiameter, the second diameter, or any combination thereof ranges from0.5 inches to 2 inches.

In some embodiments, the at least one granule liberator comprises arotary impact separator.

In some embodiments, the method further comprises using a scalpingscreen to separate particles having an average particle size of 4microns to 425 microns from the ground ASW.

In some embodiments, the step of using the scalping screen is performedbetween the steps of: grinding the ASW and screening the ground ASW.

In some embodiments, the method comprises deagglomerating the ground ASWusing a lump breaker.

In some embodiments, the step of deagglomerating the ground ASW isperformed between the steps of: grinding the ASW and screening theground ASW.

Some embodiments of the present disclosure relate to a methodcomprising: obtaining asphalt shingle waste (ASW), wherein the ASWcomprises: asphalt, limestone, granules, and impurities; grinding theASW to form ground ASW; screening the ground ASW with a rotary screener,wherein the screening of the ground ASW with the rotary screener resultsin: a first set of ASW particles, wherein the first set of ASW particleshas an average particle size of 425 microns to 6350 microns, and asecond set of ASW particles, wherein the second set of ASW particles hasan average particle size of 2 microns to 425 microns; removing at leastsome of the granules from at least one of: the first set of ASWparticles, the second set of ASW particles, or a combination thereofwith a granule liberator; grinding the first set of ASW particles,wherein the grinding of the first set of ASW particles results in athird set of ASW particles, wherein the third set of ASW particles hasan average particle size of 2 microns to 425 microns; separating thesecond and third sets of ASW particles using an air separator, whereinthe separating using the air separator results in: a fourth set of ASWparticles, wherein the fourth set of ASW particles have an averageparticle size of 250 microns to 450 microns; and a fifth set of ASWparticles, wherein the fifth set of ASW particles have an averageparticle size of 2 microns to 250 microns; grinding the fourth set ofASW particles; wherein the grinding of the fourth set of ASW particlesresults in a sixth set of ASW particles, wherein the sixth set of ASWparticles have an average particle size of 2 microns to 250 microns;wherein each of the fifth set of ASW particles and the sixth set of ASWparticles is an ASW powder having the following composition: 5 wt % to40 wt % asphalt based on a total weight of the ASW powder, and 60 wt %to 95 wt % of limestone, granules, and impurities based on the totalweight of the ASW powder; forming the ASW powder into the plurality ofbriquettes; wherein the method does not comprise a wet extraction step.

Some embodiments of the present disclosure relate to a methodcomprising: obtaining asphalt shingle waste (ASW), wherein the ASWcomprises: asphalt, limestone, granules, and impurities; grinding theASW to form ground ASW; screening the ground ASW with a rotary screener,wherein the screening of the ground ASW with the rotary screener resultsin: a first set of ASW particles, wherein the first set of ASW particleshas an average particle size of 425 microns to 6350 microns, and asecond set of ASW particles, wherein the second set of ASW particles hasan average particle size of 2 microns to 425 microns; removing at leastsome of the granules from at least one of: the first set of ASWparticles, the second set of ASW particles, or a combination thereofwith a granule liberator; grinding the first set of ASW particles,wherein the grinding of the first set of ASW particles results in athird set of ASW particles, wherein the third set of ASW particles hasan average particle size of 2 microns to 425 microns; separating thesecond and third sets of ASW particles using an air separator, whereinthe separating using the air separator results in: a fourth set of ASWparticles, wherein the fourth set of ASW particles have an averageparticle size of 250 microns to 450 microns; and a fifth set of ASWparticles, wherein the fifth set of ASW particles have an averageparticle size of 2 microns to 250 microns; grinding the fourth set ofASW particles; wherein the grinding of the fourth set of ASW particlesresults in a sixth set of ASW particles, wherein the sixth set of ASWparticles has an average particle size of 2 microns to 250 microns;wherein at least one of: the second set of ASW particles, the third setof ASW particles, the fourth set of ASW particles, the fifth set of ASWparticles, the sixth set of ASW particles or any combination thereofcomprises an ASW powder having the following composition: 5 wt % to 40wt % asphalt based on a total weight of the ASW powder, and 60 wt % to95 wt % of limestone, granules, and impurities based on the total weightof the ASW powder, obtaining the ASW powder from at least one of: thesecond set of ASW particles, the third set of ASW particles, the fourthset of ASW particles, the fifth set of ASW particles, the sixth set ofASW particles, or any combination thereof, wherein the ASW powder has anaverage particle size of 2 microns to 425 microns; feeding a sufficientamount of the ASW powder and a sufficient amount of an asphalt coatinginto at least one first mixer to form a mixture of the ASW powder andthe asphalt coating; wherein the mixture of the ASW powder and theasphalt coating has the following composition: 0.1 wt % to 50 wt % ASWpowder based on a total weight of the mixture, and 50 wt % to 99.9 wt %of the asphalt coating based on a total weight of the mixture; heatingthe mixture of the ASW powder and the asphalt coating to form a heatedmixture; wherein the heated mixture has a temperature in a range of 400°F. to 500° F.; conveying the heated mixture of the ASW powder and theasphalt coating to at least one second mixer; mixing a sufficient amountof at least one filler material with the heated mixture in the secondmixer to obtain an ASW powder filled coating; wherein the ASW powderfilled coating has the following composition: 30 wt % to 50 wt % asphaltbased on the total weight of the ASW powder filled coating, and 50 wt %to 70 wt % of: limestone powder, granules, impurities, and the at leastone filler material based on the total weight of the ASW powder filledcoating.

Some embodiments of the present disclosure relate to a methodcomprising: obtaining asphalt shingle waste (ASW), wherein the ASWcomprises: asphalt, limestone, granules, and impurities; grinding theASW to form ground ASW; screening the ground ASW with a rotary screener,wherein the screening of the ground ASW with the rotary screener resultsin: a first set of ASW particles, wherein the first set of ASW particleshas an average particle size of 425 microns to 6350 microns, and asecond set of ASW particles, wherein the second set of ASW particles hasan average particle size of 2 microns to 425 microns; removing at leastsome of the granules from at least one of: the first set of ASWparticles, the second set of ASW particles, or a combination thereofwith a granule liberator; grinding the first set of ASW particles,wherein the grinding of the first set of ASW particles results in athird set of ASW particles, wherein the third set of ASW particles hasan average particle size of 2 microns to 425 microns; separating thesecond and third sets of ASW particles using an air separator, whereinthe separating using the air separator results in: a fourth set of ASWparticles, wherein the fourth set of ASW particles have an averageparticle size of 250 microns to 450 microns; and a fifth set of ASWparticles, wherein the fifth set of ASW particles have an averageparticle size of 2 microns to 250 microns; grinding the fourth set ofASW particles; wherein the grinding of the fourth set of ASW particlesresults in a sixth set of ASW particles, wherein the sixth set of ASWparticles has an average particle size of 2 microns to 250 microns;wherein at least one of: the second set of ASW particles, the third setof ASW particles, the fourth set of ASW particles, the fifth set of ASWparticles, the sixth set of ASW particles or any combination thereofcomprises an ASW powder having the following composition: 5 wt % to 40wt % asphalt based on a total weight of the ASW powder, and 60 wt % to95 wt % of limestone, granules, and impurities based on the total weightof the ASW powder, obtaining the ASW powder from at least one of: thesecond set of ASW particles, the third set of ASW particles, the fourthset of ASW particles, the fifth set of ASW particles, the sixth set ofASW particles, or any combination thereof, wherein the ASW powder has anaverage particle size of 2 microns to 425 microns; forming the ASWpowder into a plurality of briquettes; feeding a sufficient amount ofthe plurality of briquettes and a sufficient amount of an asphaltcoating into at least one first mixer to form a mixture of the ASWpowder and the asphalt coating; wherein the mixture of the ASW powderand the asphalt coating has the following composition: 0.1 wt % to 50 wt% ASW powder based on a total weight of the mixture, and 50 wt % to 99.9wt % of the asphalt coating based on a total weight of the mixture;heating the mixture of the ASW powder and the asphalt coating to form aheated mixture; wherein the heated mixture has a temperature in a rangeof 400° F. to 500° F.; conveying the heated mixture of the ASW powderand the asphalt coating to at least one second mixer; mixing asufficient amount of at least one filler material with the heatedmixture in the second mixer to obtain an ASW powder filled coating;wherein the ASW powder filled coating has the following composition: 30wt % to 50 wt % asphalt based on the total weight of the ASW powderfilled coating, and 50 wt % to 70 wt % of: limestone powder, granules,impurities, and the at least one filler material based on the totalweight of the ASW powder filled coating.

Some embodiments of the present disclosure relate to a methodcomprising: obtaining asphalt shingle waste (ASW), wherein the ASWcomprises: asphalt, limestone powder, granules, and impurities;performing sufficient grinding steps and screening steps on the ASW toresult in ASW powder having an average particle size of 2 microns to 425microns and the following composition: 5 wt % to 40 wt % asphalt basedon a total weight of the ASW powder, 60 wt % to 95 wt % limestonepowder, granules, and impurities based on the total weight of the ASWpowder; wherein the grinding steps and screening steps do not comprisewet extraction steps; feeding a sufficient amount of the ASW powder anda sufficient amount of an asphalt coating into at least one first mixerto form a mixture of the ASW powder and the asphalt coating; wherein themixture of the ASW powder and the asphalt coating has the followingcomposition: 0.1 wt % to 50 wt % powder based on a total weight of themixture, and 50 wt % to 99.9 wt % of the asphalt coating based on atotal weight of the mixture; heating the mixture of the ASW powder andthe asphalt coating to form a heated mixture; wherein the heated mixturehas a temperature in a range of 400° F. to 500° F.; conveying the heatedmixture of the ASW powder and the asphalt coating to at least one secondmixer; mixing a sufficient amount of at least one filler material withthe heated mixture in the at least one second mixer to obtain an ASWpowder filled coating; wherein the ASW powder filled coating has thefollowing composition: 30 wt % to 50 wt % asphalt based on the totalweight of the ASW powder filled coating, and 50 wt % to 70 wt % of:limestone powder, granules, impurities, and the at least one fillermaterial based on the total weight of the ASW powder filled coating.

In some embodiments, the impurities comprise at least one of: fiberglassmat, sand, fines, marker paint, sealant, one or more adhesives, tape,plastic debris, paper debris, soil, woods, nails, or any combinationthereof.

In some embodiments, the at least one filler material is limestonepowder; and wherein the ASW powder filled coating has the followingcomposition: 30% to 50% asphalt based on the total weight of the ASWpowder filled coating, and 50% to 70% of: limestone powder, granules,and impurities based on the total weight of the ASW powder filledcoating.

In some embodiments, the ASW powder filled coating is applied to afiberglass mat to form a coated fiberglass mat.

In some embodiments, at least one of granules or sand are applied to thecoated fiberglass mat to form an asphalt shingle.

In some embodiments, the ASW consists essentially of: asphalt, limestonepowder, granules, and impurities.

In some embodiments, the ASW powder has the following composition: 25 wt% to 30 wt % asphalt based on a total weight of the ASW powder; 70 wt %to 75 wt % limestone powder, granules, and impurities based on the totalweight of the ASW powder.

In some embodiments, the asphalt coating comprises at least one of:oxidized asphalt coating, polymer modified asphalt coating, or mixturesthereof.

In some embodiments, the polymer modified asphalt coating ispoly(styrene-butadiene-styrene) (SBS) modified asphalt coating, apoly(styrene-ethylene/butylene-styrene) (SEBS) modified asphalt coating,an atactic polypropylene (APP) modified asphalt coating, an isotacticpolypropylene (IPP) modified asphalt coating, or any mixture thereof.

In some embodiments, the weight percentage of asphalt in the ASW powderfilled coating, based on the total weight of the ASW powder filledcoating, is the same as a weight percentage of asphalt in a powderfilled coating that does not contain any ASW.

In some embodiments, the mixture of the ASW powder and the asphaltcoating is not subjected to grinding or screening steps.

In some embodiments, the ASW powder filled coating comprises 1 wt % to40 wt % of the ASW powder based on the total weight of the ASW powderfilled coating.

In some embodiments, the method further comprises, after performingsufficient grinding steps and screening steps on the ASW to result inthe ASW powder, forming the ASW powder into a plurality of briquettes.

In some embodiments, during the step of feeding the sufficient amount ofthe ASW powder and the sufficient amount of an asphalt coating into atthe least one first mixer, at least a portion of the ASW powder takesthe form of a plurality of briquettes.

In some embodiments, the ASW powder filled coating has a viscosity of100 cP to 20,000 cP.

Some embodiments of the present disclosure relate to a methodcomprising: obtaining asphalt containing (AC) powder; wherein the ACpowder has an average particle size of 2 microns to 425 microns; whereinthe AC powder comprises ASW powder; wherein the AC powder has thefollowing composition: 5 wt % to 40 wt % asphalt based on a total weightof the AC powder, 60 wt % to 95 wt % limestone powder, granules, andimpurities based on the total weight of the AC powder; feeding asufficient amount of the AC powder and a sufficient amount of an asphaltcoating into at least one first mixer to form a mixture of the AC powderand the asphalt coating; wherein the mixture of the AC powder and theasphalt coating has the following composition: 0.1 wt % to 50 wt % of ACpowder based on a total weight of the mixture, and 50 wt % to 99.9 wt %of the asphalt coating based on a total weight of the mixture; heatingthe mixture of the AC powder and the asphalt coating to form a heatedmixture; wherein the heated mixture has a temperature in a range of 400°F. to 500° F.; conveying the heated mixture of the AC powder and theasphalt coating to at least one second mixer; mixing a sufficient amountof at least one filler material with the heated mixture in the secondmixer to obtain an AC powder filled coating; wherein the AC powderfilled coating has the following composition: 30 wt % to 50 wt % asphaltbased on the total weight of the AC powder filled coating, and 50 wt %to 70 wt % of: limestone powder, granules, impurities, and the at leastone filler material based on the total weight of the AC powder filledcoating.

In some embodiments, the AC powder filled coating has a viscosity of 100cP to 20,000 cP.

Some embodiments of the present disclosure relate to a methodcomprising: obtaining a plurality of briquettes, wherein each briquetteof the plurality of briquettes comprises asphalt containing (AC) powder,asphalt shingle waste (ASW) powder, or any combination thereof; whereinthe AC powder, the ASW powder, or combination thereof has an averageparticle size of 2 microns to 425 microns and the following composition:5 wt % to 40 wt % asphalt based on a total weight of the AC powder, theASW powder, or any combination thereof, 60 wt % to 95 wt % limestonepowder, granules, and impurities based on the total weight of the ACpowder, the ASW powder, or any combination thereof; feeding a sufficientamount of the briquettes and a sufficient amount of an asphalt coatinginto at least one first mixer to form a mixture of: the AC powder, theASW powder, or combination thereof; and the asphalt coating wherein themixture of: the AC powder, the ASW powder, or combination thereof; andthe asphalt coating has the following composition: 0.1 wt % to 50 wt %of the AC powder, the ASW powder, or combination thereof based on atotal weight of the mixture; and 50 wt % to 99.9 wt % of the asphaltcoating based on a total weight of the mixture; heating the mixture of:the AC powder, the ASW powder, or combination thereof; and the asphaltcoating to form a heated mixture; wherein the heated mixture has atemperature in a range of 400° F. to 500° F.; conveying the heatedmixture of the AC powder, the ASW powder, or combination thereof and theasphalt coating to at least one second mixer; mixing a sufficient amountof at least one filler material with the heated mixture in the secondmixer to obtain an AC powder filled coating, an ASW powder filledcoating or combination thereof; wherein the AC powder filled coating,the ASW powder filled coating, or combination thereof has the followingcomposition: 30 wt % to 50 wt % asphalt based on the total weight of theAC powder filled coating, the ASW powder filled coating, or combinationthereof, and 50 wt % to 70 wt % of: limestone powder, granules,impurities, and the at least one filler material based on the totalweight of the AC powder filled coating, the ASW powder filled coating,or combination thereof.

In some embodiments, obtaining the plurality of briquettes comprises:performing sufficient grinding steps and screening steps on ASW toresult in ASW powder; and compressing the ASW powder at a pressuresufficient to form the plurality of briquettes.

In some embodiments, obtaining the plurality of briquettes furthercomprises adding at least one of: limestone powder, at least one otherfiller, AC powder, or any combination thereof to the ASW powder.

In some embodiments, the pressure sufficient to form the plurality ofbriquettes ranges from 200 psi to 20,000 psi.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the disclosure are herein described, by way ofexample only, with reference to the accompanying drawings. With specificreference now to the drawings in detail, the embodiments shown are byway of example and for purposes of illustrative discussion ofembodiments of the disclosure. In this regard, the description takenwith the drawings makes apparent to those skilled in the art howembodiments of the disclosure may be practiced.

FIG. 1 is a flow diagram depicting an exemplary method of formingasphalt shingle waste (ASW) powder from asphalt shingle waste (ASW).

FIG. 2 is a non-limiting example of a briquetting process according tothe present disclosure.

FIG. 3 is a flow diagram depicting an exemplary method of forming an ASWpowder filled coating according to the present disclosure.

DETAILED DESCRIPTION

Among those benefits and improvements that have been disclosed, otherobjects and advantages of this disclosure will become apparent from thefollowing description taken in conjunction with the accompanyingfigures. Detailed embodiments of the present disclosure are disclosedherein; however, the disclosed embodiments are merely illustrative ofthe disclosure that may be embodied in various forms. In addition, eachof the examples given regarding the various embodiments of thedisclosure which are intended to be illustrative, and not restrictive.

Throughout the specification and claims, the following terms take themeanings explicitly associated herein, unless the context clearlydictates otherwise. The phrases “in one embodiment,” “in an embodiment,”and “in some embodiments” as used herein do not necessarily refer to thesame embodiment(s), though it may. Furthermore, the phrases “in anotherembodiment” and “in some other embodiments” as used herein do notnecessarily refer to a different embodiment, although it may. Allembodiments of the disclosure are intended to be combinable withoutdeparting from the scope or spirit of the disclosure.

All prior patents, publications, and test methods referenced herein areincorporated by reference in their entireties.

Definitions

As used herein, the term “based on” is not exclusive and allows forbeing based on additional factors not described, unless the contextclearly dictates otherwise. In addition, throughout the specification,the meaning of “a,” “an,” and “the” include plural references. Themeaning of “in” includes “in” and “on.”

As used herein, “asphalt shingle waste” is defined as any form ofdiscarded asphalt shingle. “Asphalt shingle waste” includes, but is notlimited to, post-manufacturing waste and post-consumer waste.

As used herein “post-consumer waste” is defined as any waste produced byan end consumer of a material stream. A non-limiting example of“post-consumer waste” is a discarded roofing shingle from a residentialor commercial roof. Another non-limiting example of “post-consumerwaste” is contractor waste including, but not limited to, surplus newmaterial, damaged material, and scrap from cut shingles duringinstallation. Yet another non-limiting example of “post-consumer waste”is at least one of: distributor waste, retail waste, or any combinationthereof, including, but not limited to, damaged shingle products, agedinventory of shingles, and customer returns.

As used herein, “post-manufacturing waste” is defined as waste producedprior to reaching the end consumer of a material stream. A non-limitingexample of “post-manufacturing waste” is any shingle waste generatedduring the production, handling, transportation or other method ofgeneration prior to installation on a roof of a consumer.Post-manufacturing waste may include production waste such as, but notlimited to, partial shingles and coated fiberglass mat with or withoutgranules.

As used herein “grinding” is the reduction of particles by size.Non-limiting examples of grinding include, but are not limited to,crushing, shredding, chopping, milling (e.g., hammermilling), the like,and combinations thereof.

As used herein, “screening” is the separation of particles by size.Non-limiting examples of screening include, but are not limited to,vibratory screening, rotary screening, the like, and combinationsthereof.

As used herein a “screener” is a screening device that is configured toperform at least one screening step.

As used herein, a “rotary screener” is any type of screening device thatseparates particles by size through rotation of at least a portion ofthe screening device.

As used herein, a “trommel screener” is a rotary screening device thatincludes a rotating drum. Trommel screeners are not vibratory screeners.In some embodiments, a trommel screener separates particles by size asthe particles pass through the rotating drum. In some embodiments,particles that are smaller than openings in the drum fall through theopenings. In some embodiments, particles that are larger than theopenings in the drum do not fall through the openings.

As used herein, a “vibratory screener” is any type of screening devicethat separates particles by size through vibration of at least a portionof the screening device.

As used herein a “sizing shaker” is a type of vibratory screener thatincludes at least one vibrating tray. In some embodiments, a sizingshaker separates particles by size as the at least one vibrating trayvibrates. In some embodiments, particles that are smaller than openingsin the tray fall through the openings. In some embodiments, particlesthat are larger than the openings in the tray do not fall through theopenings. In some embodiments, a sizing shaker includes at least oneball tray.

As used herein a “ball tray” is a tray that includes balls within one ormore compartments of the tray. In some embodiments, at least one balltray may be placed underneath the at least one vibrating tray of avibratory screener (e.g., a sizing shaker) to reduce clogging ofparticles within the openings of the tray. In some embodiments, as theat least one vibrating tray vibrates, the balls of the at least one balltray strike an underside of the vibrating tray, thereby dislodging theclogged particles.

As used herein, an “air separator” is a device configured to receive asuspension of particles in air and separate the particles by at leastone of, size, density or a combination thereof. In some embodiments, an“air separator” may include at least one of a “cyclone air separator” ora “mechanical air separator.” In some embodiments, a “cyclone airseparator” can operate in a vertically oriented configuration (i.e.,with a top of the cyclone air separator pointing towards the sky andwith a bottom of the cyclone air separator pointing towards the ground).In some embodiments, the suspension of particles may be introduced intoa chamber, such that flow of the suspension into the chamber creates aspiral vortex. In some embodiments, a “mechanical air separator”includes one or more spinning blades (e.g., centrifugally rotatingblades). In some embodiments, a fraction of particles from thesuspension pass through the spinning blades, while a remainder of theparticles from the suspension do not pass through the plurality ofspinning blades.

As used herein, “wet extraction steps” are steps that include, but arenot limited to, at least one of: the introduction of a solvent into amixture of particles, the formation of a liquid from a mixture ofparticles, or any combination thereof.

As used herein, “dry grinding steps” are grinding steps that do notinclude wet extraction steps.

As used herein, “average particle size” is defined as “the smallest sizesieve openings according to the U.S. Standard Test Sieve Series where90% of the particles pass through the sieve.” For example, particleshaving an average particle size of 425 microns means at least 90% of theparticles pass through a 40 U.S. Standard Test Sieve having 425 micronsieve openings and less than 90% of the particles pass through a 45 U.S.Standard Test Sieve having 355 micron sieve openings.

As used herein, “a granule liberator” is any device configured toseparate granules from a mixture of particles, a powder, or anycombination thereof. A non-limiting example of a granule liberator is arotary impact separator (RIS). Other non-limiting examples of granuleliberators include any size separation device described herein, or anydensity separation device described herein.

As used herein, a “rotary impact separator” is a device having rotatingelements attached to a central shaft, such that the device is configuredto impact feed material. In some embodiments, the rotating elements mayinclude, but are not limited to paddles, chains, knives, or othershapes. In some embodiments, the rotating elements may be located at oneor more locations along the central shaft to facilitate impact of thefeed material. In some embodiments, the rotary impact separator mayfurther include screens on at least one of the bottom or the sides ofthe unit to collect the impacted material. In some embodiments, aftercollection, the impacted material exits the rotary impact separator viaan exit chute or equivalent. In some embodiments, the rotary impactseparator may further include dams, baffles, breakers, and adjustablegates. In some embodiments, the rotary impact separator can also be usedto help control flow and residence time of the material within the unit.A non-limiting example of a rotary impact separator according to certainembodiments is shown in U.S. Patent Application Publication No.2017/0305038, which is incorporated by reference in its entirety.

As used herein, a “powder” is a mixture of particles produced by sizereduction steps including, but not limited to, grinding, crushing, ordisintegration, the like, or any combination thereof, of a solidsubstance.

As used herein, “asphalt shingle waste (ASW) powder” is a mixture ofparticles produced by size reduction steps including, but not limitedto, grinding, crushing, or disintegration, the like, or any combinationthereof, of asphalt shingle waste.

As used herein, a “scalping screen” is a screening device comprising aseries of conveyor belts. In some embodiments, the scalping screen isconfigured to receive particles in various sizes and stockpile resultingscreened particles off one or more ends of the conveyor belts.

As used herein, a “lump breaker” is any device configured tode-agglomerate particles.

As used herein, the term “briquette” broadly refers to any solidagglomeration of particles that includes ASW powder, AC powder (asdefined herein, infra), or any combination thereof. In some embodiments,a briquette may include a binding agent. In some embodiments, abriquette may exclude binding agents. In some embodiments, in any methodstep where an ASW powder, an AC powder, or any combination thereof isused, the ASW powder, an AC powder, or any combination thereof may bepartially or completely replaced with a plurality of briquettes.

As used herein the term “briquetting” refers to any process of forming abriquette. In some embodiments, a briquetting process may include theaddition of a binding agent. In some embodiments, a briquetting processmay exclude addition of any binding agents.

As used herein, “wet extraction steps” are steps that include, but arenot limited to, at least one of: the introduction of a solvent into amixture of particles, the formation of a liquid from a mixture ofparticles, or any combination thereof.

As used herein, “asphalt coating” is defined as any form of processedasphalt, where “processed asphalt” is formed by subjecting asphalt to atleast one processing step. The at least one processing step can include,but is not limited to, oxidation, dehydrogenation, condensation,polymerization, the like, or any combination thereof.

As used herein, “asphalt containing (AC) powder” is a mixture ofparticles produced by size reduction steps including, but not limitedto, grinding, crushing, or disintegration, the like, or any combinationthereof, of at least one asphalt containing composition. Examples of ACpowder include, but are not limited to, ASW powder, powders formed fromprocessed asphalt, powders formed from unprocessed asphalt, or anycombination or mixture thereof.

As used herein, “oxidized asphalt coating” is defined as a form ofprocessed asphalt that is created by oxidizing asphalt. A non-limitingexample of an oxidation procedure is air-blowing, in which air is blowninto asphalt at a sufficient temperature (e.g., from 450° F. to 500° F.)to oxidize the asphalt. Other non-limiting examples of oxidationprocedures are described in U.S. Pat. Nos. 7,901,563 and 9,556,383, eachof which are incorporated by reference in their entireties.

As used herein, “polymer modified asphalt coating” is defined as a formof processed asphalt that is created by adding at least one polymer toasphalt. A non-limiting example of a polymer modification procedure isemulsification, in which at least one polymer is mixed with asphalt at asufficient temperature (e.g., from 250° F. to 350° F.) to form anemulsion. Other non-limiting examples of polymer modification proceduresare described in U.S. Pat. No. 8,901,211, which is incorporated byreference in its entirety. In yet other embodiments, the polymer forms acolloid suspension, colloid solution, or dispersion with the asphalt.

As used herein, “softening point” is the temperature at which a materialsoftens beyond a predetermined reference softness. Softening point ismeasured herein according to ASTM-D-3461.

As used herein, “penetration point” is the vertical distance penetratedby the point of a standard needle into asphalt under specific conditionsof load, time and temperature. Penetration point is measured hereinaccording to ASTM D-5.

As used herein, “viscosity” is a measure of a fluid's resistance to flowat a given shear rate and temperature. Viscosity is measured herein inaccordance with ASTM D-4402 by using a Brookfield LVT viscometer at 400°F. with a #31 spindle at 30 RPM.

Exemplary Methods of Processing Asphalt Shingle Waste (ASW)

Some embodiments of the present disclosure relate to methods ofprocessing asphalt shingle waste (ASW).

In some embodiments, an exemplary method according to the presentdisclosure includes obtaining ASW. In some embodiments, the ASWcomprises asphalt, limestone, granules, and impurities. In someembodiments, the ASW consists essentially of asphalt, limestone,granules, and impurities. In some embodiments, the ASW consists ofasphalt, limestone, granules, and impurities. In some embodiments, theimpurities comprise least one of: fiberglass mat sand, fines, markerpaint, sealant, one or more adhesives, tape, plastic debris, paperdebris, soil, woods, nails, or any combination thereof.

In some embodiments, an exemplary method according to the presentdisclosure comprises a step of grinding the ASW to form ground ASW. Insome embodiments, the ground ASW may be stored for a period of time. Insome such embodiments, the ground ASW may agglomerate. In some suchembodiments, the ASW may be deagglomerated using a lump breaker.

In some embodiments, a portion of the ground ASW may have a sufficientlysmall particle size, such that this portion of the ground ASW may be feddirectly to a downstream step of an exemplary method described herein.Put differently. In some embodiments, the portion of the ground ASWhaving the sufficiently small particle size may “skip” one or moredownstream grinding or separation steps detailed herein. In some of suchembodiments, the portion of the ground ASW that is sufficiently small insize may be separated from a remainder of the ground ASW using ascalping screen.

In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 425microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 5 microns to 425microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 10 microns to 425microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 25 microns to 425microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 50 microns to 425microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 100 microns to 425microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 200 microns to 425microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 300 microns to 425microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 400 microns to 425microns.

In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 400microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 300microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 200microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 100microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 50microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 25microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 10microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 2 microns to 5microns.

In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 5 microns to 400microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 10 microns to 300microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 25 microns to 200microns. In some non-limiting embodiments, the sufficiently small sizecorresponds to an average particle size ranging from 50 microns to 100microns.

In some embodiments, an exemplary method according to the presentdisclosure comprises screening the ground ASW with a rotary screener. Insome embodiments, the rotary screener is a trommel screener. In someembodiments, an exemplary method according to the present disclosuredoes not comprise any steps of screening with a vibratory screener. Insome embodiments, an exemplary method according to the presentdisclosure does not comprise any steps of screening with a screeningdevice that comprises at least one ball tray. In some embodiments, anexemplary method according to the present disclosure does not compriseany steps of screening with a sizing shaker.

In some embodiments, the screening of the ground ASW with the rotaryscreener results in a first set of ASW particles and a second set of ASWparticles.

In some embodiments, the first set of ASW particles has an averageparticle size of 425 microns to 6350 microns. In some embodiments, thefirst set of ASW particles has an average particle size of 500 micronsto 6350 microns. In some embodiments, the first set of ASW particles hasan average particle size of 750 microns to 6350 microns. In someembodiments, the first set of ASW particles has an average particle sizeof 1000 microns to 6350 microns. In some embodiments, the first set ofASW particles has an average particle size of 2000 microns to 6350microns. In some embodiments, the first set of ASW particles has anaverage particle size of 5000 microns to 6350 microns. In someembodiments, the first set of ASW particles has an average particle sizeof 6000 microns to 6350 microns.

In some embodiments, the first set of ASW particles has an averageparticle size of 425 microns to 6000 microns. In some embodiments, thefirst set of ASW particles has an average particle size of 425 micronsto 5000 microns. In some embodiments, the first set of ASW particles hasan average particle size of 425 microns to 2000 microns. In someembodiments, the first set of ASW particles has an average particle sizeof 425 microns to 1000 microns. In some embodiments, the first set ofASW particles has an average particle size of 425 microns to 750microns. In some embodiments, the first set of ASW particles has anaverage particle size of 425 microns to 500 microns.

In some embodiments, the first set of ASW particles has an averageparticle size of 500 microns to 6000 microns. In some embodiments, thefirst set of ASW particles has an average particle size of 750 micronsto 5000 microns. In some embodiments, the first set of ASW particles hasan average particle size of 1000 microns to 2000 microns.

In some embodiments, the second set of ASW particles has an averageparticle size of 2 microns to 425 microns. In some embodiments, thesecond set of ASW particles has an average particle size of 5 microns to425 microns. In some embodiments, the second set of ASW particles has anaverage particle size of 10 microns to 425 microns. In some embodiments,the second set of ASW particles has an average particle size of 25microns to 425 microns. In some embodiments, the second set of ASWparticles has an average particle size of 50 microns to 425 microns. Insome embodiments, the second set of ASW particles has an averageparticle size of 75 microns to 425 microns. In some embodiments, thesecond set of ASW particles has an average particle size of 100 micronsto 425 microns. In some embodiments, the second set of ASW particles hasan average particle size of 200 microns to 425 microns. In someembodiments, the second set of ASW particles has an average particlesize of 300 microns to 425 microns. In some embodiments, the second setof ASW particles has an average particle size of 400 microns to 425microns.

In some embodiments, the second set of ASW particles has an averageparticle size of 2 microns to 400 microns. In some embodiments, thesecond set of ASW particles has an average particle size of 2 microns to300 microns. In some embodiments, the second set of ASW particles has anaverage particle size of 2 microns to 200 microns. In some embodiments,the second set of ASW particles has an average particle size of 2microns to 100 microns. In some embodiments, the second set of ASWparticles has an average particle size of 2 microns to 75 microns. Insome embodiments, the second set of ASW particles has an averageparticle size of 2 microns to 50 microns. In some embodiments, thesecond set of ASW particles has an average particle size of 2 microns to25 microns. In some embodiments, the second set of ASW particles has anaverage particle size of 2 microns to 10 microns. In some embodiments,the second set of ASW particles has an average particle size of 2microns to 5 microns.

In some embodiments, the second set of ASW particles has an averageparticle size of 5 microns to 400 microns. In some embodiments, thesecond set of ASW particles has an average particle size of 10 micronsto 300 microns. In some embodiments, the second set of ASW particles hasan average particle size of 25 microns to 200 microns. In someembodiments, the second set of ASW particles has an average particlesize of 75 microns to 100 microns.

In some embodiments, the first set of ASW particles has an averageparticle size that is greater than the average particle size of thesecond set of ASW particles.

In some embodiments, an exemplary method according to the presentdisclosure includes removing at least some of the granules from at leastone of the first set of ASW particles, the second set of ASW particles,or a combination thereof with a at least one granule liberator such as,but not limited to at least one rotary impact separator. In someembodiments, an exemplary method according to the present disclosureincludes removing all the granules from at least one of the first set ofASW particles, the second set of ASW particles, or a combination thereofwith an MS.

In some embodiments, an exemplary method according to the presentdisclosure includes removing 20% to 95% of the granules from at leastone of the first set of ASW particles, the second set of ASW particles,or a combination thereof with at least one granule liberator. In someembodiments, an exemplary method according to the present disclosureincludes removing 40% to 95% of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof with at least one granule liberator. In someembodiments, an exemplary method according to the present disclosureincludes removing 60% to 95% of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof with at least one granule liberator. In someembodiments, an exemplary method according to the present disclosureincludes removing 80% to 95% of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof with at least one granule liberator. In someembodiments, an exemplary method according to the present disclosureincludes removing 90% to 95% of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof with at least one granule liberator.

In some embodiments, an exemplary method according to the presentdisclosure includes removing 20% to 90% of the granules from at leastone of the first set of ASW particles, the second set of ASW particles,or a combination thereof with at least one granule liberator. In someembodiments, an exemplary method according to the present disclosureincludes removing 20% to 80% of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof with at least one granule liberator. In someembodiments, an exemplary method according to the present disclosureincludes removing 20% to 60% of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof with at least one granule liberator. In someembodiments, an exemplary method according to the present disclosureincludes removing 20% to 40% of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof with at least one granule liberator.

In some embodiments, an exemplary method according to the presentdisclosure includes removing 40% to 90% of the granules from at leastone of the first set of ASW particles, the second set of ASW particles,or a combination thereof with at least one granule liberator. In someembodiments, an exemplary method according to the present disclosureincludes removing 60% to 80% of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof with at least one granule liberator.

In some embodiments, an exemplary method according to the presentdisclosure includes removing at least some of the granules from at leastone of the first set of ASW particles, the second set of ASW particles,or a combination thereof with two or more granule liberators. In someembodiments, the two or more granule liberators are operated in series.In yet other embodiments, the two or more granule liberators areoperated in parallel.

In some embodiments, at least some of the ASW particles from at leastone of the first set of ASW particles, the second set of ASW particles,or any combination thereof may remain in a mixture with the granulesthat are removed using at least one granule liberator. In suchembodiments, at least some of the remaining ASW particles may beseparated from the mixture using at least one density separationtechnique, at least one size separation technique, or any combinationthereof. Non-limiting examples of the at least one density separationtechnique, the at least one size separation technique, or anycombination thereof include any screening technique described herein,any air separation technique described herein (e.g., cyclone airseparation, mechanical air separation), air classification, vacuumseparation, the like, or any combination thereof.

In some embodiments, the at least one granule liberator may remove sand,fiberglass, backing, mat substrate, non-asphaltic materials, or anycombination thereof.

In some embodiments, the at least one density separation technique, theat least one size separation technique, or any combination thereof maybe used to remove at least some of the granules from at least one of thefirst set of ASW particles, the second set of ASW particles, or acombination thereof, in addition to or as an alternative granuleliberation mechanism (i.e., other than the RIS). In some embodiments, aplurality of density separation techniques, a plurality of sizeseparation techniques, or any combination thereof may be used to removeat least some of the granules from at least one of the first set of ASWparticles, the second set of ASW particles, or a combination thereof.

In some embodiments, an exemplary method according to the presentdisclosure includes removing at least some of the granules from at leastone of the first set of ASW particles, the second set of ASW particles,or a combination thereof with a plurality of density separationtechniques, a plurality of size separation techniques, or anycombination thereof. In embodiments, the plurality of density separationtechniques, the plurality of size separation techniques, or anycombination thereof are performed in series. In yet other embodiments,the plurality of density separation techniques, the plurality of sizeseparation techniques, or any combination thereof are performed inparallel.

In some embodiments, at least some of the granules may be reused inroofing products. In some embodiments, at least some of the granules maybe reused in manufacture of one or more roofing shingles or roofingshingle components. In some non-limiting embodiments, at least some ofthe granules may be reused for a headlap of a roofing shingle, a backingof a roofing shingle, or any combination thereof.

In some embodiments, the first set of ASW particles is subjected to agrinding step. In some embodiments, the step of grinding the first setof ASW particles results in a third set of ASW particles.

In some embodiments, the third set of ASW particles has an averageparticle size of 2 microns to 425 microns. In some embodiments, thethird set of ASW particles has an average particle size of 5 microns to425 microns. In some embodiments, the third set of ASW particles has anaverage particle size of 10 microns to 425 microns. In some embodiments,the third set of ASW particles has an average particle size of 25microns to 425 microns. In some embodiments, the third set of ASWparticles has an average particle size of 50 microns to 425 microns. Insome embodiments, the third set of ASW particles has an average particlesize of 75 microns to 425 microns. In some embodiments, the third set ofASW particles has an average particle size of 100 microns to 425microns. In some embodiments, the third set of ASW particles has anaverage particle size of 200 microns to 425 microns. In someembodiments, the third set of ASW particles has an average particle sizeof 300 microns to 425 microns. In some embodiments, the third set of ASWparticles has an average particle size of 400 microns to 425 microns.

In some embodiments, the third set of ASW particles has an averageparticle size of 2 microns to 400 microns. In some embodiments, thethird set of ASW particles has an average particle size of 2 microns to300 microns. In some embodiments, the third set of ASW particles has anaverage particle size of 2 microns to 200 microns. In some embodiments,the third set of ASW particles has an average particle size of 2 micronsto 100 microns. In some embodiments, the third set of ASW particles hasan average particle size of 2 microns to 75 microns. In someembodiments, the third set of ASW particles has an average particle sizeof 2 microns to 50 microns. In some embodiments, the third set of ASWparticles has an average particle size of 2 microns to 25 microns. Insome embodiments, the third set of ASW particles has an average particlesize of 2 microns to 10 microns. In some embodiments, the third set ofASW particles has an average particle size of 2 microns to 5 microns.

In some embodiments, the third set of ASW particles has an averageparticle size of 5 microns to 400 microns. In some embodiments, thethird set of ASW particles has an average particle size of 10 microns to300 microns. In some embodiments, the third set of ASW particles has anaverage particle size of 25 microns to 200 microns. In some embodiments,the third set of ASW particles has an average particle size of 75microns to 100 microns.

In some embodiments, the second set of ASW particles and the third setof ASW particles are combined to form a combination of the second andthird sets of ASW particles. In some embodiments, the second set of ASWparticles and the third set of ASW particles are not combined.

In some embodiments, the combination of the second and third sets of ASWparticles are separated using an air separator. In some embodiments,each of the second set of ASW particles and the third set of ASWparticles is individually separated using the air separator. In someembodiments, the air separator is a mechanical air separator. In someembodiments, the air separator is a cyclone air separator.

In some embodiments, the separating using the air separator results in afourth set of ASW particles and a fifth set of ASW particles.

In some embodiments, the fourth set of ASW particles has an averageparticle size of 250 microns to 450 microns. In some embodiments, thefourth set of ASW particles has an average particle size of 300 micronsto 450 microns. In some embodiments, the fourth set of ASW particles hasan average particle size of 350 microns to 450 microns. In someembodiments, the fourth set of ASW particles has an average particlesize of 400 microns to 450 microns.

In some embodiments, the fourth set of ASW particles has an averageparticle size of 250 microns to 400 microns. In some embodiments, thefourth set of ASW particles has an average particle size of 250 micronsto 350 microns. In some embodiments, the fourth set of ASW particles hasan average particle size of 250 microns to 300 microns.

In some embodiments, the fourth set of ASW particles has an averageparticle size of 300 microns to 400 microns.

In some embodiments, the fifth set of ASW particles has an averageparticle size of 2 microns to 250 microns. In some embodiments, thefifth set of ASW particles has an average particle size of 5 microns to250 microns. In some embodiments, the fifth set of ASW particles has anaverage particle size of 10 microns to 250 microns. In some embodiments,the fifth set of ASW particles has an average particle size of 25microns to 250 microns. In some embodiments, the fifth set of ASWparticles has an average particle size of 50 microns to 250 microns. Insome embodiments, the fifth set of ASW particles has an average particlesize of 75 microns to 250 microns. In some embodiments, the fifth set ofASW particles has an average particle size of 100 microns to 250microns. In some embodiments, the fifth set of ASW particles has anaverage particle size of 150 microns to 250 microns. In someembodiments, the fifth set of ASW particles has an average particle sizeof 200 microns to 250 microns.

In some embodiments, the fifth set of ASW particles has an averageparticle size of 2 microns to 200 microns. In some embodiments, thefifth set of ASW particles has an average particle size of 2 microns to150 microns. In some embodiments, the fifth set of ASW particles has anaverage particle size of 2 microns to 100 microns. In some embodiments,the fifth set of ASW particles has an average particle size of 2 micronsto 75 microns. In some embodiments, the fifth set of ASW particles hasan average particle size of 2 microns to 50 microns. In someembodiments, the fifth set of ASW particles has an average particle sizeof 2 microns to 25 microns. In some embodiments, the fifth set of ASWparticles has an average particle size of 2 microns to 10 microns. Insome embodiments, the fifth set of ASW particles has an average particlesize of 2 microns to 5 microns.

In some embodiments, the fourth set of ASW particles has an averageparticle size that is greater than the average particle size of thefifth set of ASW particles.

In some embodiments, an exemplary method according to the presentdisclosure includes grinding the fourth set of ASW particles. In someembodiments, the grinding of the fourth set of ASW particles results ina sixth set of ASW particles.

In some embodiments, the sixth set of ASW particles has an averageparticle size of 2 microns to 250 microns. In some embodiments, thesixth set of ASW particles has an average particle size of 5 microns to250 microns. In some embodiments, the sixth set of ASW particles has anaverage particle size of 10 microns to 250 microns. In some embodiments,the sixth set of ASW particles has an average particle size of 25microns to 250 microns. In some embodiments, the sixth set of ASWparticles has an average particle size of 50 microns to 250 microns. Insome embodiments, the sixth set of ASW particles has an average particlesize of 75 microns to 250 microns. In some embodiments, the sixth set ofASW particles has an average particle size of 100 microns to 250microns. In some embodiments, the sixth set of ASW particles has anaverage particle size of 150 microns to 250 microns. In someembodiments, the sixth set of ASW particles has an average particle sizeof 200 microns to 250 microns.

In some embodiments, the sixth set of ASW particles has an averageparticle size of 2 microns to 200 microns. In some embodiments, thesixth set of ASW particles has an average particle size of 2 microns to150 microns. In some embodiments, the sixth set of ASW particles has anaverage particle size of 2 microns to 100 microns. In some embodiments,the sixth set of ASW particles has an average particle size of 2 micronsto 75 microns. In some embodiments, the sixth set of ASW particles hasan average particle size of 2 microns to 50 microns. In someembodiments, the sixth set of ASW particles has an average particle sizeof 2 microns to 25 microns. In some embodiments, the sixth set of ASWparticles has an average particle size of 2 microns to 10 microns. Insome embodiments, the sixth set of ASW particles has an average particlesize of 2 microns to 5 microns.

In some embodiments, the fifth set of ASW particles and the sixth set ofASW particles are combined. In some embodiments, the fifth set of ASWparticles and the sixth set of ASW particles are not combined.

In some embodiments, the combining of the fifth set of ASW particles andthe sixth set of ASW particles results in an ASW powder. In someembodiments, each of the fifth set of ASW particles and the sixth set ofASW particles is an ASW powder.

In some embodiments, at least one of: the second set of ASW particles,the third set of ASW particles, the fourth set of ASW particles, thefifth set of ASW particles, the sixth set of ASW particles, or anycombination thereof comprises the ASW powder. In some such embodiments,the ASW powder may be separated from at least one of: the second set ofASW particles, the third set of ASW particles, the fourth set of ASWparticles, the fifth set of ASW particles, the sixth set of ASWparticles or any combination thereof using any separation technique(e.g., screening, density separation, size separation) described hereinor any combination of separation techniques described herein.

In some embodiments, the ASW powder is combined with an asphalt coating(e.g., an oxidized asphalt coating or a polymer modified asphaltcoating) to form a partially filled asphalt coating. In someembodiments, limestone or at least one other filler material may beadded to the partially filled asphalt coating to form a filled asphaltcoating. In some embodiments, the filled asphalt coating is incorporatedinto a roofing shingle.

In some embodiments, the ASW powder comprises 5 wt % to 40 wt % asphaltbased on a total weight of the ASW powder. In some embodiments, the ASWpowder comprises 10 wt % to 40 wt % asphalt based on a total weight ofthe ASW powder. In some embodiments, the ASW powder comprises 15 wt % to40 wt % asphalt based on a total weight of the ASW powder. In someembodiments, the ASW powder comprises 20 wt % to 40 wt % asphalt basedon a total weight of the ASW powder. In some embodiments, the ASW powdercomprises 25 wt % to 40 wt % asphalt based on a total weight of the ASWpowder. In some embodiments, the ASW powder comprises 30 wt % to 40 wt %asphalt based on a total weight of the ASW powder. In some embodiments,the ASW powder comprises 35 wt % to 40 wt % asphalt based on a totalweight of the ASW powder.

In some embodiments, the ASW powder comprises 5 wt % to 35 wt % asphaltbased on a total weight of the ASW powder. In some embodiments, the ASWpowder comprises 5 wt % to 30 wt % asphalt based on a total weight ofthe ASW powder. In some embodiments, the ASW powder comprises 5 wt % to20 wt % asphalt based on a total weight of the ASW powder. In someembodiments, the ASW powder comprises 5 wt % to 15 wt % asphalt based ona total weight of the ASW powder. In some embodiments, the ASW powdercomprises 5 wt % to 10 wt % asphalt based on a total weight of the ASWpowder.

In some embodiments, the ASW powder comprises 10 wt % to 35 wt % asphaltbased on a total weight of the ASW powder. In some embodiments, the ASWpowder comprises 15 wt % to 30 wt % asphalt based on a total weight ofthe ASW powder. In some embodiments, the ASW powder comprises 20 wt % to25 wt % asphalt based on a total weight of the ASW powder.

In some embodiments, the ASW powder comprises 60 wt % to 95 wt % oflimestone, granules, and impurities based on the total weight of the ASWpowder. In some embodiments, the ASW powder comprises 65 wt % to 95 wt %of limestone, granules, and impurities based on the total weight of theASW powder. In some embodiments, the ASW powder comprises 70 wt % to 95wt % of limestone, granules, and impurities based on the total weight ofthe ASW powder. In some embodiments, the ASW powder comprises 75 wt % to95 wt % of limestone, granules, and impurities based on the total weightof the ASW powder. In some embodiments, the ASW powder comprises 80 wt %to 95 wt % of limestone, granules, and impurities based on the totalweight of the ASW powder. In some embodiments, the ASW powder comprises85 wt % to 95 wt % of limestone, granules, and impurities based on thetotal weight of the ASW powder. In some embodiments, the ASW powdercomprises 90 wt % to 95 wt % of limestone, granules, and impuritiesbased on the total weight of the ASW powder.

In some embodiments, the ASW powder comprises 60 wt % to 90 wt % oflimestone, granules, and impurities based on the total weight of the ASWpowder. In some embodiments, the ASW powder comprises 60 wt % to 85 wt %of limestone, granules, and impurities based on the total weight of theASW powder. In some embodiments, the ASW powder comprises 60 wt % to 80wt % of limestone, granules, and impurities based on the total weight ofthe ASW powder. In some embodiments, the ASW powder comprises 60 wt % to75 wt % of limestone, granules, and impurities based on the total weightof the ASW powder. In some embodiments, the ASW powder comprises 60 wt %to 70 wt % of limestone, granules, and impurities based on the totalweight of the ASW powder. In some embodiments, the ASW powder comprises60 wt % to 65 wt % of limestone, granules, and impurities based on thetotal weight of the ASW powder.

In some embodiments, the ASW powder comprises 65 wt % to 90 wt % oflimestone, granules, and impurities based on the total weight of the ASWpowder. In some embodiments, the ASW powder comprises 70 wt % to 85 wt %of limestone, granules, and impurities based on the total weight of theASW powder. In some embodiments, the ASW powder comprises 75 wt % to 80wt % of limestone, granules, and impurities based on the total weight ofthe ASW powder.

In some embodiments, the ASW powder comprises 5 wt % to 40 wt % asphaltbased on a total weight of the ASW powder with the remainder limestone,granules, and impurities. In some embodiments, the ASW powder comprises10 wt % to 40 wt % asphalt based on a total weight of the ASW powderwith the remainder limestone, granules, and impurities. In someembodiments, the ASW powder comprises 15 wt % to 40 wt % asphalt basedon a total weight of the ASW powder with the remainder limestone,granules, and impurities. In some embodiments, the ASW powder comprises20 wt % to 40 wt % asphalt based on a total weight of the ASW powderwith the remainder limestone, granules, and impurities. In someembodiments, the ASW powder comprises 25 wt % to 40 wt % asphalt basedon a total weight of the ASW powder with the remainder limestone,granules, and impurities. In some embodiments, the ASW powder comprises30 wt % to 40 wt % asphalt based on a total weight of the ASW powderwith the remainder limestone, granules, and impurities. In someembodiments, the ASW powder comprises 35 wt % to 40 wt % asphalt basedon a total weight of the ASW powder with the remainder limestone,granules, and impurities.

In some embodiments, the ASW powder comprises 5 wt % to 35 wt % asphaltbased on a total weight of the ASW powder with the remainder limestone,granules, and impurities. In some embodiments, the ASW powder comprises5 wt % to 30 wt % asphalt based on a total weight of the ASW powder withthe remainder limestone, granules, and impurities. In some embodiments,the ASW powder comprises 5 wt % to 20 wt % asphalt based on a totalweight of the ASW powder with the remainder limestone, granules, andimpurities. In some embodiments, the ASW powder comprises 5 wt % to 15wt % asphalt based on a total weight of the ASW powder with theremainder limestone, granules, and impurities. In some embodiments, theASW powder comprises 5 wt % to 10 wt % asphalt based on a total weightof the ASW powder with the remainder limestone, granules, andimpurities.

In some embodiments, an exemplary method of the present disclosure doesnot comprise a wet extraction step.

In embodiments, the method further comprises an air stripping stepbefore one or more of the screening steps detailed herein.

In some embodiments, one or more dust collection steps may be performedat any stage of the method (i.e., before, during, after, or between anystep(s) of an exemplary method described herein) without departing fromthe scope of the present disclosure. In some embodiments, residual wasteproducts from the ASW may be removed at any stage of the process (i.e.,before, during, after, or between any step(s) of an exemplary methoddescribed herein) without departing from the scope of the presentdisclosure. A non-limiting example of a residual waste product is aresidual plastic material from the asphalt shingles, such as, but notlimited to, residual portions of fiberglass mat.

In some embodiments, at least one aeration device may be added at anystage of the process (i.e., before, during, after, or between anystep(s) of an exemplary method described herein) without departing fromthe scope of the present disclosure. In some embodiments, the at leastone aeration device includes, but is not limited to, at least one airseparator described herein, at least one aspirator, or any combinationthereof.

In some embodiments an exemplary method according to the presentdisclosure may be performed in any order.

In some non-limiting embodiments, an exemplary method of the presentdisclosure is performed in the following order: (a) obtaining the ASW;(b) grinding the ASW to form ground ASW; (c) screening the ground ASWwith the rotary screener to form the first set of ASW particles and thesecond set of ASW particles; (d) removing at least some of the granulesof the ASW from at least one of the first set of ASW particles, thesecond set of ASW particles, or a combination thereof with at least onegranule liberator, such as at least one rotary impact separator; (e)grinding the first set of ASW particles to result in a third set ofparticles; (f) separating the combination of the second and third setsof ASW particles using an air separator to result in a fourth set of ASWparticles and a fifth set of ASW particles; (g) grinding the fourth setof ASW particles to result in a sixth set of particles.

In some embodiments, an exemplary method of the present disclosure doesnot comprise a grinding step after step (g). In some embodiments, anexemplary method of the present disclosure does not comprise anygrinding steps other than steps (b), (e), and (g). In some embodiments,an exemplary method of the present disclosure does not comprise ascreening step after step (f).

An exemplary embodiment of the present disclosure is shown in FIG. 1. Asshown in the non-limiting exemplary embodiment of FIG. 1, asphaltshingle waste (ASW) 101 may be obtained. In some embodiments, the ASW101 is subjected to a grinding step 102 to form ground ASW particles. Insome embodiments, the ground ASW particles 103 are subjected to ascreening step 104 to form a first set of ASW particles 105 and a secondset of ASW particles 106. In some embodiments, the screening step 104 isperformed with a rotary screener. In some embodiments, some or all ofthe granules are removed from the first set of ASW particles 105 usingrotary impact separator 107. While not depicted in FIG. 1, rotary impactseparator 107 may also remove some or all of the granules from thesecond set of ASW particles 106. In some embodiments, the first set ofparticles 105 is subjected to a grinding step 108, so as to form a thirdset of ASW particles 109. In some embodiments the second set of ASWparticles 106 and the third set of ASW particles 109 may be combined toform a combination 110 of the second and third sets of ASW particles. Insome embodiments, the combination 110 of the second and third sets ofASW particles 110 is fed into an air separator 111, where thecombination 110 of the second and third sets of ASW particles areseparated into a fourth set of ASW particles 112 and a fifth set of ASWparticles 113. In some embodiments, the fourth set of ASW particles 112is subjected to a grinding step 114, so as to form a sixth set of ASWparticles 115. In some embodiments, the fifth set of ASW particles 113and the sixth set of ASW particles 115 are combined to form ASW powder116. In some embodiments, ASW powder 116 is combined with an asphaltcoating to form a partially filled asphalt coating, as shown in FIG. 3and described herein, infra. In some embodiments, limestone or otherfiller material may be added to the partially filled asphalt coating toform a filled asphalt coating, as shown in FIG. 3 and described herein,infra. In some embodiments, the filled asphalt coating (not shown) isincorporated into a roofing shingle (not shown).

Exemplary Briquetting Methods

In some embodiments, the ASW powder is formed into a plurality ofbriquettes. In some embodiments, each briquette of the plurality ofbriquettes comprises the ASW powder. In some embodiments, some of theplurality of briquettes comprises the ASW powder.

In some embodiments, each briquette of the plurality of briquettescomprises at least one of: the ASW powder, AC powder (as describedherein), or any combination thereof. In some embodiments, some of theplurality of briquettes comprises the ASW powder, the AC powder, or anycombination thereof. In some embodiments, the plurality of briquettes isformed after performing the grinding steps and screening steps(described herein) on the ASW to result in the ASW powder.

In some embodiments, limestone powder or other filler is added to atleast one of: the ASW powder, the AC powder, or any combination thereofto form the plurality of briquettes. In some embodiments, the pluralityof briquettes may be obtained (e.g., delivered, purchased, obtained fromstorage, formed, compressed, or any combination thereof).

In some embodiments, the plurality of briquettes is formed bycompressing the ASW powder and the limestone powder and at a pressuresufficient to form the plurality of briquettes. In some embodiments, theplurality of briquettes is formed by compressing the ASW powder at apressure sufficient to form the plurality of briquettes. Any suitablecompression device may be used, including but not limited to, a piston,a briquetting machine, a plurality of compression wheels, or anycombination thereof.

In some embodiments, the pressure sufficient to form the plurality ofbriquettes ranges from 200 psi to 20,000 psi. In some embodiments, thepressure sufficient to form the plurality of briquettes ranges from 500psi to 20,000 psi. In some embodiments, the pressure sufficient to formthe plurality of briquettes ranges from 1,000 psi to 20,000 psi. In someembodiments, the pressure sufficient to form the plurality of briquettesranges from 5,000 psi to 20,000 psi. In some embodiments, the pressuresufficient to form the plurality of briquettes ranges from 10,000 psi to20,000 psi. In some embodiments, the pressure sufficient to form theplurality of briquettes ranges from 15,000 psi to 20,000 psi.

In some embodiments, the pressure sufficient to form the plurality ofbriquettes ranges from 200 psi to 15,000 psi. In some embodiments, thepressure sufficient to form the plurality of briquettes ranges from 200psi to 10,000 psi. In some embodiments, the pressure sufficient to formthe plurality of briquettes ranges from 200 psi to 5,000 psi. In someembodiments, the pressure sufficient to form the plurality of briquettesranges from 200 psi to 1,000 psi. In some embodiments, the pressuresufficient to form the plurality of briquettes ranges from 200 psi to5000 psi.

In some embodiments, the pressure sufficient to form the plurality ofbriquettes ranges from 500 psi to 15,000 psi. In some embodiments, thepressure sufficient to form the plurality of briquettes ranges from1,000 psi to 10,000 psi. In some embodiments, the pressure sufficient toform the plurality of briquettes is 500 psi.

The plurality of briquettes may be any shape. In some embodiments, eachbriquette the plurality of briquettes is spherical. In some embodiments,each briquette of the plurality of briquettes is an oblate spheroid(i.e., an ellipsoid). In some embodiments the plurality of briquettesmay include brqiuettes having at least one of the following non-limitingshapes: a rectangular prism, a cube, a cone, a tetrahedron, apentahedron, a hexahedron, a dodecahedron, a torus, or any combinationthereof.

The plurality of briquettes may have any size. In some embodiments, eachbriquette of the plurality of briquettes may be spherical with adiameter in a range of 0.5 inches to 2 inches. In some embodiments, eachbriquette of the plurality of briquettes may be spherical with adiameter in a range of 1 inch to 2 inches. In some embodiments, eachbriquette of the plurality of briquettes may be spherical with adiameter in a range of 1.5 inches to 2 inches. In some embodiments, eachbriquette of the plurality of briquettes may be spherical with adiameter in a range of 0.5 inches to 1.5 inches. In some embodiments,each briquette of the plurality of briquettes may be spherical with adiameter in a range of 0.5 inches to 1 inch. In some embodiments, eachbriquette of the plurality of briquettes may be spherical with adiameter in a range of 1 inch to 1.5 inches.

In some embodiments, each briquette of the plurality of briquettes maybe an oblate spheroid with at least one of: a first diameter, a seconddiameter, or any combination thereof having a range of 0.5 inches to 2inches. In some embodiments, each briquette of the plurality ofbriquettes may be an oblate spheroid with at least one of: a firstdiameter, a second diameter, or any combination thereof having a rangeof 1 inch to 2 inches. In some embodiments, each briquette of theplurality of briquettes may be an oblate spheroid with at least one of:a first diameter, a second diameter, or any combination thereof having arange of 1.5 inches to 2 inches In some embodiments, each briquette ofthe plurality of briquettes may be an oblate spheroid with at least oneof: a first diameter, a second diameter, or any combination thereofhaving a range of 0.5 inches to 1.5 inches In some embodiments, eachbriquette of the plurality of briquettes may be an oblate spheroid withat least one of: a first diameter, a second diameter, or any combinationthereof having a range of 0.5 inches to 1 inch. In some embodiments,each briquette of the plurality of briquettes may be an oblate spheroidwith at least one of: a first diameter, a second diameter, or anycombination thereof having a range of 1 inch to 1.5 inches.

In some embodiments, during the feeding of at least one of: the ACpowder, the ASW powder, or any combination thereof into the at least onefirst mixer (as described herein, infra), at least a portion of the ACpowder or the ASW powder is in the form of a briquette. In someembodiments, during the feeding of into the at least one first mixer,all of the AC powder, all of the ASW powder, or all of both is in theform of a briquette.

FIG. 2 is a non-limiting example of a briquetting method according tothe present disclosure. As shown, in some embodiments, limestone powder,other filler, or combination thereof 201 coats compression wheels 203.The ASW powder, AC powder, or combination thereof 202 is fed between thecoated compression wheels 203. The compression wheels 203 apply asufficient pressure to: the limestone powder, other filler, orcombination thereof 201; and the ASW powder, AC powder, or combinationthereof 202, so as to form a plurality of briquettes 204.

Exemplary Methods of forming Asphalt Shingle Waste (ASW) Powder FilledCoatings

Some embodiments of the present disclosure relate to methods of formingasphalt shingle waste powder filled coatings from asphalt shingle waste.In some embodiments, any steps of forming asphalt shingle waste powderdescribed herein, any steps of forming briquettes described herein, orany combination thereof, may be combined with any of the methods offorming asphalt shingle waste powder filled coatings described herein.In some embodiments, the method is a continuous process. In someembodiments, the method is a batch process. In some embodiments, themethod is a semi-continuous process. In some embodiments, the method isa semi-batch process.

In some embodiments of the present disclosure, asphalt shingle waste(ASW) is obtained. In some embodiments, the ASW comprises asphalt,limestone powder, granules, and impurities. In some embodiments, the ASWconsists essentially of asphalt, limestone powder, granules, andimpurities. In some embodiments, the ASW consists of asphalt, limestonepowder, granules, and impurities.

In some embodiments, the impurities comprise at least one of: fiberglassmat sand, fines, marker paint, sealant, one or more adhesives, tape,plastic debris, paper debris, soil, woods, nails, or any combinationthereof.

In some embodiments, sufficient dry grinding and screening steps(including but not limited to any dry grinding and screening stepsdefined herein, supra) are performed on the ASW to result in ASW powderhaving an average particle size of 2 microns to 425 microns. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having an average particle size of 2microns to 325 microns. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder havingan average particle size of 2 microns to 225 microns. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having an average particle size of 2microns to 125 microns. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder havingan average particle size of 2 microns to 100 microns. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having an average particle size of 2microns to 75 microns. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder havingan average particle size of 2 microns to 50 microns. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having an average particle size of 2microns to 25 microns. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder havingan average particle size of 2 microns to 20 microns. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having an average particle size of 2microns to 15 microns. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder havingan average particle size of 2 microns to 10 microns. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having an average particle size of 2microns to 5 microns.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 5 microns to 425 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 10 microns to 425 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 15 microns to 425 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 20 microns to 425 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 25 microns to 425 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 50 microns to 425 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 75 microns to 425 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 100 microns to 425 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 125 microns to 425 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 225 microns to 425 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 325 microns to 425 microns.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 5 microns to 325 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 10 microns to 225 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 25 microns to 125 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 50 microns to 100 microns.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 10 microns to 250 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 10 microns to 200 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 10 microns to 150 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 10 microns to 100 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 10 microns to 75 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 10 microns to 50 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 10 microns to 25 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 10 microns to 20 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 10 microns to 15 microns.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 15 microns to 250 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 20 microns to 250 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 25 microns to 250 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 50 microns to 250 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 75 microns to 250 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 100 microns to 250 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 150 microns to 250 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 200 microns to 250 microns.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 20 microns to 200 microns. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having an average particle size of 40 microns to 100 microns. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having an average particlesize of 80 microns to 90 microns.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having 5 wt % to 40 wt %asphalt based on a total weight of the powder. In some embodiments,sufficient dry grinding and screening steps are performed on the ASW toresult in ASW powder having 10 wt % to 40 wt % asphalt based on a totalweight of the powder. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder having15 wt % to 40 wt % asphalt based on a total weight of the powder. Insome embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having 20 wt % to 40 wt %asphalt based on a total weight of the ASW powder. In some embodiments,sufficient dry grinding and screening steps are performed on the ASW toresult in ASW powder having 25 wt % to 40 wt % asphalt based on a totalweight of the ASW powder. In some embodiments, sufficient dry grindingand screening steps are performed on the ASW to result in ASW powderhaving 30 wt % to 40 wt % asphalt based on a total weight of the ASWpowder. In some embodiments, sufficient dry grinding and screening stepsare performed on the ASW to result in ASW powder having 35 wt % to 40 wt% asphalt based on a total weight of the ASW powder.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having 5 wt % to 35 wt %asphalt based on a total weight of the ASW powder. In some embodiments,sufficient dry grinding and screening steps are performed on the ASW toresult in ASW powder having 5 wt % to 30 wt % asphalt based on a totalweight of the ASW powder. In some embodiments, sufficient dry grindingand screening steps are performed on the ASW to result in ASW powderhaving 5 wt % to 25 wt % asphalt based on a total weight of the ASWpowder. In some embodiments, sufficient dry grinding and screening stepsare performed on the ASW to result in ASW powder having 5 wt % to 20 wt% asphalt based on a total weight of the ASW powder. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having 5 wt % to 15 wt % asphaltbased on a total weight of the ASW powder. In some embodiments,sufficient dry grinding and screening steps are performed on the ASW toresult in ASW powder having 5 wt % to 10 wt % asphalt based on a totalweight of the ASW powder.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having 10 wt % to 35 wt %asphalt based on a total weight of the powder. In some embodiments,sufficient dry grinding and screening steps are performed on the ASW toresult in ASW powder having 15 wt % to 30 wt % asphalt based on a totalweight of the powder. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder having20 wt % to 25 wt % asphalt based on a total weight of the powder.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having 60 wt % to 95 wt %limestone powder, granules, and impurities based on the total weight ofthe ASW powder. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder having65 wt % to 95 wt % limestone powder, granules, and impurities based onthe total weight of the ASW powder. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having 70 wt % to 95 wt % limestone powder, granules, andimpurities based on the total weight of the ASW powder. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having 75 wt % to 95 wt % limestonepowder, granules, and impurities based on the total weight of the ASWpowder. In some embodiments, sufficient dry grinding and screening stepsare performed on the ASW to result in ASW powder having 80 wt % to 95 wt% limestone powder, granules, and impurities based on the total weightof the ASW powder. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder having85 wt % to 95 wt % limestone powder, granules, and impurities based onthe total weight of the ASW powder. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having 90 wt % to 95 wt % limestone powder, granules, andimpurities based on the total weight of the ASW powder.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having 60 wt % to 90 wt %limestone powder, granules, and impurities based on the total weight ofthe ASW powder. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder having60 wt % to 85 wt % limestone powder, granules, and impurities based onthe total weight of the ASW powder. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having 60 wt % to 80 wt % limestone powder, granules, andimpurities based on the total weight of the ASW powder. In someembodiments, sufficient dry grinding and screening steps are performedon the ASW to result in ASW powder having 60 wt % to 75 wt % limestonepowder, granules, and impurities based on the total weight of the ASWpowder. In some embodiments, sufficient dry grinding and screening stepsare performed on the ASW to result in ASW powder having 60 wt % to 70 wt% limestone powder, granules, and impurities based on the total weightof the ASW powder. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder having60 wt % to 65 wt % limestone powder, granules, and impurities based onthe total weight of the ASW powder.

In some embodiments, sufficient dry grinding and screening steps areperformed on the ASW to result in ASW powder having 65 wt % to 90 wt %limestone powder, granules, and impurities based on the total weight ofthe ASW powder. In some embodiments, sufficient dry grinding andscreening steps are performed on the ASW to result in ASW powder having70 wt % to 85 wt % limestone powder, granules, and impurities based onthe total weight of the ASW powder. In some embodiments, sufficient drygrinding and screening steps are performed on the ASW to result in ASWpowder having 75 wt % to 80 wt % limestone powder, granules, andimpurities based on the total weight of the ASW powder.

In some embodiments, the grinding steps and screening steps do notcomprise wet extraction steps.

In some embodiments, a sufficient amount of the ASW powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the ASW powder and the asphalt coating thatcomprises 0.1 wt % to 50 wt % of ASW powder based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the ASW powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the ASW powder and the asphalt coatingthat comprises 1 wt % to 50 wt % of ASW powder based on a total weightof the mixture. In some embodiments, a sufficient amount of the ASWpowder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the ASW powder and theasphalt coating that comprises 2 wt % to 50 wt % of ASW powder based ona total weight of the mixture. In some embodiments, a sufficient amountof the ASW powder and a sufficient amount of an asphalt coating areadded to at least one first mixer to form a mixture of the ASW powderand the asphalt coating that comprises 5 wt % to 50 wt % of ASW powderbased on a total weight of the mixture. In some embodiments, asufficient amount of the ASW powder and a sufficient amount of anasphalt coating are added to at least one first mixer to form a mixtureof the ASW powder and the asphalt coating that comprises 10 wt % to 50wt % of ASW powder based on a total weight of the mixture. In someembodiments, a sufficient amount of the ASW powder and a sufficientamount of an asphalt coating are added to at least one first mixer toform a mixture of the ASW powder and the asphalt coating that comprises20 wt % to 50 wt % of ASW powder based on a total weight of the mixture.In some embodiments, a sufficient amount of the ASW powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the ASW powder and the asphalt coating thatcomprises 30 wt % to 50 wt % of ASW powder based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the ASW powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the ASW powder and the asphalt coatingthat comprises 40 wt % to 50 wt % of ASW powder based on a total weightof the mixture.

In some embodiments, a sufficient amount of the ASW powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the ASW powder and the asphalt coating thatcomprises 0.1 wt % to 40 wt % of ASW powder based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the ASW powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the ASW powder and the asphalt coatingthat comprises 0.1 wt % to 30 wt % of ASW powder based on a total weightof the mixture. In some embodiments, a sufficient amount of the ASWpowder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the ASW powder and theasphalt coating that comprises 0.1 wt % to 20 wt % of ASW powder basedon a total weight of the mixture. In some embodiments, a sufficientamount of the ASW powder and a sufficient amount of an asphalt coatingare added to at least one first mixer to form a mixture of the ASWpowder and the asphalt coating that comprises 0.1 wt % to 10 wt % of ASWpowder based on a total weight of the mixture. In some embodiments, asufficient amount of the ASW powder and a sufficient amount of anasphalt coating are added to at least one first mixer to form a mixtureof the ASW powder and the asphalt coating that comprises 0.1 wt % to 5wt % of ASW powder based on a total weight of the mixture. In someembodiments, a sufficient amount of the ASW powder and a sufficientamount of an asphalt coating are added to at least one first mixer toform a mixture of the ASW powder and the asphalt coating that comprises0.1 wt % to 2 wt % of ASW powder based on a total weight of the mixture.In some embodiments, a sufficient amount of the ASW powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the ASW powder and the asphalt coating thatcomprises 0.1 wt % to 1 wt % of ASW powder based on a total weight ofthe mixture.

In some embodiments, a sufficient amount of the ASW powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the ASW powder and the asphalt coating thatcomprises 1 wt % to 40 wt % of ASW powder based on a total weight of themixture. In some embodiments, a sufficient amount of the ASW powder anda sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the ASW powder and the asphalt coatingthat comprises 2 wt % to 30 wt % of ASW powder based on a total weightof the mixture. In some embodiments, a sufficient amount of the ASWpowder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the ASW powder and theasphalt coating that comprises 5 wt % to 20 wt % of ASW powder based ona total weight of the mixture. In some embodiments, a sufficient amountof the ASW powder and a sufficient amount of an asphalt coating areadded to at least one first mixer to form a mixture of the ASW powderand the asphalt coating that comprises 10 wt % to 15 wt % of ASW powderbased on a total weight of the mixture.

In some embodiments, a sufficient amount of the ASW powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the ASW powder and the asphalt coating thatcomprises 50 wt % to 99.9 wt % of the asphalt coating based on a totalweight of the mixture. In some embodiments, a sufficient amount of theASW powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the ASW powder and theasphalt coating that comprises 60 wt % to 99.9 wt % of the asphaltcoating based on a total weight of the mixture. In some embodiments, asufficient amount of the ASW powder and a sufficient amount of anasphalt coating are added to at least one first mixer to form a mixtureof the ASW powder and the asphalt coating that comprises 70 wt % to 99.9wt % of the asphalt coating based on a total weight of the mixture. Insome embodiments, a sufficient amount of the ASW powder and a sufficientamount of an asphalt coating are added to at least one first mixer toform a mixture of the ASW powder and the asphalt coating that comprises80 wt % to 99.9 wt % of the asphalt coating based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the ASW powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the ASW powder and the asphalt coatingthat comprises 90 wt % to 99.9 wt % of the asphalt coating based on atotal weight of the mixture. In some embodiments, a sufficient amount ofthe ASW powder and a sufficient amount of an asphalt coating are addedto at least one first mixer to form a mixture of the ASW powder and theasphalt coating that comprises 95 wt % to 99.9 wt % of the asphaltcoating based on a total weight of the mixture. In some embodiments, asufficient amount of the ASW powder and a sufficient amount of anasphalt coating are added to at least one first mixer to form a mixtureof the ASW powder and the asphalt coating that comprises 99 wt % to 99.9wt % of the asphalt coating based on a total weight of the mixture.

In some embodiments, a sufficient amount of the ASW powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the ASW powder and the asphalt coating thatcomprises 50 wt % to 99 wt % of the asphalt coating based on a totalweight of the mixture. In some embodiments, a sufficient amount of theASW powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the ASW powder and theasphalt coating that comprises 50 wt % to 95 wt % of the asphalt coatingbased on a total weight of the mixture. In some embodiments, asufficient amount of the ASW powder and a sufficient amount of anasphalt coating are added to at least one first mixer to form a mixtureof the ASW powder and the asphalt coating that comprises 50 wt % to 90wt % of the asphalt coating based on a total weight of the mixture. Insome embodiments, a sufficient amount of the ASW powder and a sufficientamount of an asphalt coating are added to at least one first mixer toform a mixture of the ASW powder and the asphalt coating that comprises50 wt % to 80 wt % of the asphalt coating based on a total weight of themixture. In some embodiments, a sufficient amount of the ASW powder anda sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the ASW powder and the asphalt coatingthat comprises 50 wt % to 70 wt % of the asphalt coating based on atotal weight of the mixture. In some embodiments, a sufficient amount ofthe ASW powder and a sufficient amount of an asphalt coating are addedto at least one first mixer to form a mixture of the ASW powder and theasphalt coating that comprises 50 wt % to 60 wt % of the asphalt coatingbased on a total weight of the mixture.

In some embodiments, a sufficient amount of the ASW powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the ASW powder and the asphalt coating thatcomprises 60 wt % to 99 wt % of the asphalt coating based on a totalweight of the mixture. In some embodiments, a sufficient amount of theASW powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the ASW powder and theasphalt coating that comprises 70 wt % to 95 wt % of the asphalt coatingbased on a total weight of the mixture. In some embodiments, asufficient amount of the ASW powder and a sufficient amount of anasphalt coating are added to at least one first mixer to form a mixtureof the ASW powder and the asphalt coating that comprises 80 wt % to 90wt % of the asphalt coating based on a total weight of the mixture.

In some embodiments, the mixture of the ASW powder and the asphaltcoating is not subjected to grinding or screening steps. In someembodiments, the mixture of the ASW powder and the asphalt coating isnot subjected to grinding steps. In some embodiments, the mixture of theASW powder and the asphalt coating is not subjected to screening steps.

In some embodiments, asphalt containing (AC) powder is obtained. In someembodiments, the AC powder comprises ASW powder. In some embodiments theAC powder does not comprise ASW powder. In some embodiments, the ACpowder comprises a mixture of ASW powder and non-ASW powder. In someembodiments, the AC powder is formed into briquettes as describedherein. In some embodiments, the AC powder is obtained as a pre-formedbriquette.

In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 0.1 wt % to 50 wt % of AC powder based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the AC powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the AC powder and the asphalt coatingthat comprises 1 wt % to 50 wt % of AC powder based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the AC powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the AC powder and the asphalt coatingthat comprises 2 wt % to 50 wt % of AC powder based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the AC powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the AC powder and the asphalt coatingthat comprises 5 wt % to 50 wt % of AC powder based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the AC powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the AC powder and the asphalt coatingthat comprises 10 wt % to 50 wt % of AC powder based on a total weightof the mixture. In some embodiments, a sufficient amount of the ACpowder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 20 wt % to 50 wt % of AC powder based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 30 wt % to 50 wt % of AC powder based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 40 wt % to 50 wt % of AC powder based on a totalweight of the mixture.

In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 0.1 wt % to 40 wt % of AC powder based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the AC powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the AC powder and the asphalt coatingthat comprises 0.1 wt % to 30 wt % of AC powder based on a total weightof the mixture. In some embodiments, a sufficient amount of the ACpowder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 0.1 wt % to 20 wt % of AC powder based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 0.1 wt % to 10 wt % of AC powder based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 0.1 wt % to 5 wt % of AC powder based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 0.1 wt % to 2 wt % of AC powder based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 0.1 wt % to 1 wt % of AC powder based on a totalweight of the mixture.

In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 1 wt % to 40 wt % of AC powder based on a total weight of themixture. In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 2 wt % to 30 wt % of AC powder based on a total weight of themixture. In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 5 wt % to 20 wt % of AC powder based on a total weight of themixture. In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 10 wt % to 15 wt % of AC powder based on a total weight of themixture.

In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 50 wt % to 99.9 wt % of the asphalt coating based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 60 wt % to 99.9 wt % of the asphalt coating basedon a total weight of the mixture. In some embodiments, a sufficientamount of the AC powder and a sufficient amount of an asphalt coatingare added to at least one first mixer to form a mixture of the AC powderand the asphalt coating that comprises 70 wt % to 99.9 wt % of theasphalt coating based on a total weight of the mixture. In someembodiments, a sufficient amount of the AC powder and a sufficientamount of an asphalt coating are added to at least one first mixer toform a mixture of the AC powder and the asphalt coating that comprises80 wt % to 99.9 wt % of the asphalt coating based on a total weight ofthe mixture. In some embodiments, a sufficient amount of the AC powderand a sufficient amount of an asphalt coating are added to at least onefirst mixer to form a mixture of the AC powder and the asphalt coatingthat comprises 90 wt % to 99.9 wt % of the asphalt coating based on atotal weight of the mixture. In some embodiments, a sufficient amount ofthe AC powder and a sufficient amount of an asphalt coating are added toat least one first mixer to form a mixture of the AC powder and theasphalt coating that comprises 95 wt % to 99.9 wt % of the asphaltcoating based on a total weight of the mixture. In some embodiments, asufficient amount of the AC powder and a sufficient amount of an asphaltcoating are added to at least one first mixer to form a mixture of theAC powder and the asphalt coating that comprises 99 wt % to 99.9 wt % ofthe asphalt coating based on a total weight of the mixture.

In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 50 wt % to 99 wt % of the asphalt coating based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 50 wt % to 95 wt % of the asphalt coating basedon a total weight of the mixture. In some embodiments, a sufficientamount of the AC powder and a sufficient amount of an asphalt coatingare added to at least one first mixer to form a mixture of the AC powderand the asphalt coating that comprises 50 wt % to 90 wt % of the asphaltcoating based on a total weight of the mixture. In some embodiments, asufficient amount of the AC powder and a sufficient amount of an asphaltcoating are added to at least one first mixer to form a mixture of theAC powder and the asphalt coating that comprises 50 wt % to 80 wt % ofthe asphalt coating based on a total weight of the mixture. In someembodiments, a sufficient amount of the AC powder and a sufficientamount of an asphalt coating are added to at least one first mixer toform a mixture of the AC powder and the asphalt coating that comprises50 wt % to 70 wt % of the asphalt coating based on a total weight of themixture. In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 50 wt % to 60 wt % of the asphalt coating based on a totalweight of the mixture.

In some embodiments, a sufficient amount of the AC powder and asufficient amount of an asphalt coating are added to at least one firstmixer to form a mixture of the AC powder and the asphalt coating thatcomprises 60 wt % to 99 wt % of the asphalt coating based on a totalweight of the mixture. In some embodiments, a sufficient amount of theAC powder and a sufficient amount of an asphalt coating are added to atleast one first mixer to form a mixture of the AC powder and the asphaltcoating that comprises 70 wt % to 95 wt % of the asphalt coating basedon a total weight of the mixture. In some embodiments, a sufficientamount of the AC powder and a sufficient amount of an asphalt coatingare added to at least one first mixer to form a mixture of the AC powderand the asphalt coating that comprises 80 wt % to 90 wt % of the asphaltcoating based on a total weight of the mixture.

Non-limiting examples of mixers that can be used as the at least firstone mixer include, but are not limited to, vertically or horizontallyagitated tanks, high or low shear tubular mixers, horizontal paddlemixers, screw transport mixers, continuous high shear mixers,progressive cavity mixing pumps or any combination thereof.

In some embodiments, the at least one first mixer comprises a pluralityof first mixers. In some embodiments, the at least one first mixercomprises at least two first mixers. In some embodiments, the at leastone first mixer comprises at least three first mixers. In someembodiments, the at least one first mixer comprises at least four firstmixers. In some embodiments, the at least one first mixer comprises atleast five first mixers. In some embodiments, the at least one firstmixer comprises at least ten first mixers. In some embodiments, the atleast one first mixer comprises at least twenty first mixers. In someembodiments, the at least one first mixer comprises at least fifty firstmixers. In some embodiments, the at least one first mixer comprises atleast one-hundred first mixers.

In some embodiments, the at least one first mixer consists of a singlemixer. In some embodiments, the at least one first mixer consists of twofirst mixers. In some embodiments, the at least one first mixer consistsof three first mixers. In some embodiments, the at least one first mixerconsists of four first mixers. In some embodiments, the at least onefirst mixer consists of five first mixers. In some embodiments, the atleast one first mixer consists of ten first mixers. In some embodiments,the at least one first mixer consists of twenty first mixers. In someembodiments, the at least one first mixer consists of fifty firstmixers. In some embodiments, the at least one first mixer consists ofone-hundred first mixers.

In some embodiments, the asphalt coating comprises at least one of:oxidized asphalt coating, polymer modified asphalt coating, or mixturesthereof.

In some embodiments, the oxidized asphalt coating is obtained using anasphalt oxidation process. Non-limiting examples of suitable asphaltoxidation processes are described herein, infra. In some embodiments,the oxidized asphalt coating is fed directly from an oxidation processinto the at least one first mixer. In some embodiments, the oxidizedasphalt coating is oxidized “off-site” and fed from a storage tank intothe at least one first mixer.

In some embodiments, the oxidized asphalt coating has a softening pointof 190° F. to 250° F. In some embodiments, the oxidized asphalt coatinghas a softening point of 200° F. to 250° F. In some embodiments, theoxidized asphalt coating has a softening point of 210° F. to 250° F. Insome embodiments, the oxidized asphalt coating has a softening point of220° F. to 250° F. In some embodiments, the oxidized asphalt coating hasa softening point of 230° F. to 250° F. In some embodiments, theoxidized asphalt coating has a softening point of 240° F. to 250° F.

In some embodiments, the oxidized asphalt coating has a softening pointof 190° F. to 240° F. In some embodiments, the oxidized asphalt coatinghas a softening point of 190° F. to 230° F. In some embodiments, theoxidized asphalt coating has a softening point of 190° F. to 220° F. Insome embodiments, the oxidized asphalt coating has a softening point of190° F. to 210° F. In some embodiments, the oxidized asphalt coating hasa softening point of 190° F. to 200° F.

In some embodiments, the oxidized asphalt coating has a softening pointof 200° F. to 240° F. In some embodiments, the oxidized asphalt coatinghas a softening point of 210° F. to 230° F.

In some embodiments, the oxidized asphalt coating has a penetrationpoint of 15 mm to 45 mm. In some embodiments, the oxidized asphaltcoating has a penetration point of 20 mm to 45 mm. In some embodiments,the oxidized asphalt coating has a penetration point of 25 mm to 45 mm.In some embodiments, the oxidized asphalt coating has a penetrationpoint of 30 mm to 45 mm. In some embodiments, the oxidized asphaltcoating has a penetration point of 35 mm to 45 mm. In some embodiments,the oxidized asphalt coating has a penetration point of 40 mm to 45 mm.

In some embodiments, the oxidized asphalt coating has a penetrationpoint of 15 mm to 40 mm. In some embodiments, the oxidized asphaltcoating has a penetration point of 15 mm to 35 mm. In some embodiments,the oxidized asphalt coating has a penetration point of 15 mm to 30 mm.In some embodiments, the oxidized asphalt coating has a penetrationpoint of 15 mm to 25 mm. In some embodiments, the oxidized asphaltcoating has a penetration point of 15 mm to 20 mm.

In some embodiments, the oxidized asphalt coating has a penetrationpoint of 20 mm to 40 mm. In some embodiments, the oxidized asphaltcoating has a penetration point of 25 mm to 35 mm.

In some embodiments, the oxidized asphalt coating has a viscosity of 200cP to 1,000 cP. In some embodiments, the oxidized asphalt coating has aviscosity of 300 cP to 1,000 cP. In some embodiments, the oxidizedasphalt coating has a viscosity of 400 cP to 1,000 cP. In someembodiments, the oxidized asphalt coating has a viscosity of 500 cP to1,000 cP. In some embodiments, the oxidized asphalt coating has aviscosity of 600 cP to 1,000 cP. In some embodiments, the oxidizedasphalt coating has a viscosity of 700 cP to 1,000 cP. In someembodiments, the oxidized asphalt coating has a viscosity of 800 cP to1,000 cP. In some embodiments, the oxidized asphalt coating has aviscosity of 900 cP to 1,000 cP.

In some embodiments, the oxidized asphalt coating has a viscosity of 200cP to 1,000 cP. In some embodiments, the oxidized asphalt coating has aviscosity of 200 cP to 900 cP. In some embodiments, the oxidized asphaltcoating has a viscosity of 200 cP to 800 cP. In some embodiments, theoxidized asphalt coating has a viscosity of 200 cP to 700 cP. In someembodiments, the oxidized asphalt coating has a viscosity of 200 cP to600 cP. In some embodiments, the oxidized asphalt coating has aviscosity of 200 cP to 500 cP. In some embodiments, the oxidized asphaltcoating has a viscosity of 200 cP to 400 cP. In some embodiments, theoxidized asphalt coating has a viscosity of 200 cP to 300 cP.

In some embodiments, the oxidized asphalt coating has a viscosity of 300cP to 900 cP. In some embodiments, the oxidized asphalt coating has aviscosity of 400 cP to 800 cP. In some embodiments, the oxidized asphaltcoating has a viscosity of 500 cP to 700 cP.

In some embodiments, the polymer modified asphalt coating is apoly(styrene-butadiene-styrene) (SBS) modified asphalt coating, apoly(styrene-ethylene/butylene-styrene) (SEBS) modified asphalt coating,an atactic polypropylene (APP) modified asphalt coating, an isotacticpolypropylene (IPP) modified asphalt coating, or any mixture thereof.

In some embodiments, the polymer modified asphalt coating comprises 3 wt% to 12 wt % of at least one polymer by weight of the polymer modifiedasphalt coating. In some embodiments, the polymer modified asphaltcoating comprises 4 wt % to 12 wt % of at least one polymer by weight ofthe polymer modified asphalt coating. In some embodiments, the polymermodified asphalt coating comprises 5 wt % to 12 wt % of at least onepolymer by weight of the polymer modified asphalt coating. In someembodiments, the polymer modified asphalt coating comprises 6 wt % to 12wt % of at least one polymer by weight of the polymer modified asphaltcoating. In some embodiments, the polymer modified asphalt coatingcomprises 7 wt % to 12 wt % of at least one polymer by weight of thepolymer modified asphalt coating. In some embodiments, the polymermodified asphalt coating comprises 8 wt % to 12 wt % of at least onepolymer by weight of the polymer modified asphalt coating. In someembodiments, the polymer modified asphalt coating comprises 9 wt % to 12wt % of at least one polymer by weight of the polymer modified asphaltcoating. In some embodiments, the polymer modified asphalt coatingcomprises 10 wt % to 12 wt % of at least one polymer by weight of thepolymer modified asphalt coating. In some embodiments, the polymermodified asphalt coating comprises 11 wt % to 12 wt % of at least onepolymer by weight of the polymer modified asphalt coating.

In some embodiments, the polymer modified asphalt coating comprises 3 wt% to 11 wt % of at least one polymer by weight of the polymer modifiedasphalt coating. In some embodiments, the polymer modified asphaltcoating comprises 3 wt % to 10 wt % of at least one polymer by weight ofthe polymer modified asphalt coating. In some embodiments, the polymermodified asphalt coating comprises 3 wt % to 9 wt % of at least onepolymer by weight of the polymer modified asphalt coating. In someembodiments, the polymer modified asphalt coating comprises 3 wt % to 8wt % of at least one polymer by weight of the polymer modified asphaltcoating. In some embodiments, the polymer modified asphalt coatingcomprises 3 wt % to 7 wt % of at least one polymer by weight of thepolymer modified asphalt coating. In some embodiments, the polymermodified asphalt coating comprises 3 wt % to 6 wt % of at least onepolymer by weight of the polymer modified asphalt coating. In someembodiments, the polymer modified asphalt coating comprises 3 wt % to 5wt % of at least one polymer by weight of the polymer modified asphaltcoating. In some embodiments, the polymer modified asphalt coatingcomprises 3 wt % to 4 wt % of at least one polymer by weight of thepolymer modified asphalt coating.

In some embodiments, the polymer modified asphalt coating comprises 4 wt% to 11 wt % of at least one polymer by weight of the polymer modifiedasphalt coating. In some embodiments, the polymer modified asphaltcoating comprises 5 wt % to 10 wt % of at least one polymer by weight ofthe polymer modified asphalt coating. In some embodiments, the polymermodified asphalt coating comprises 6 wt % to 9 wt % of at least onepolymer by weight of the polymer modified asphalt coating. In someembodiments, the polymer modified asphalt coating comprises 7 wt % to 8wt % of at least one polymer by weight of the polymer modified asphaltcoating.

In some embodiments, the polymer modified asphalt coating has asoftening point of 190° F. to 250° F. In some embodiments, the polymermodified asphalt coating has a softening point of 200° F. to 250° F. Insome embodiments, the polymer modified asphalt coating has a softeningpoint of 210° F. to 250° F. In some embodiments, the polymer modifiedasphalt coating has a softening point of 220° F. to 250° F. In someembodiments, the polymer modified asphalt coating has a softening pointof 230° F. to 250° F. In some embodiments, the polymer modified asphaltcoating has a softening point of 240° F. to 250° F.

In some embodiments, the polymer modified asphalt coating has asoftening point of 190° F. to 240° F. In some embodiments, the polymermodified asphalt coating has a softening point of 190° F. to 230° F. Insome embodiments, the polymer modified asphalt coating has a softeningpoint of 190° F. to 220° F. In some embodiments, the polymer modifiedasphalt coating has a softening point of 190° F. to 210° F. In someembodiments, the polymer modified asphalt coating has a softening pointof 190° F. to 200° F.

In some embodiments, the polymer modified asphalt coating has asoftening point of 200° F. to 240° F. In some embodiments, the polymermodified asphalt coating has a softening point of 210° F. to 230° F.

In some embodiments, the polymer modified asphalt coating has apenetration point of 15 mm to 45 mm. In some embodiments, the polymermodified asphalt coating has a penetration point of 20 mm to 45 mm. Insome embodiments, the polymer modified asphalt coating has a penetrationpoint of 25 mm to 45 mm. In some embodiments, the polymer modifiedasphalt coating has a penetration point of 30 mm to 45 mm. In someembodiments, the polymer modified asphalt coating has a penetrationpoint of 35 mm to 45 mm. In some embodiments, the polymer modifiedasphalt coating has a penetration point of 40 mm to 45 mm.

In some embodiments, the polymer modified asphalt coating has apenetration point of 15 mm to 40 mm. In some embodiments, the polymermodified asphalt coating has a penetration point of 15 mm to 35 mm. Insome embodiments, the polymer modified asphalt coating has a penetrationpoint of 15 mm to 30 mm. In some embodiments, the polymer modifiedasphalt coating has a penetration point of 15 mm to 25 mm. In someembodiments, the polymer modified asphalt coating has a penetrationpoint of 15 mm to 20 mm.

In some embodiments, the polymer modified asphalt coating has apenetration point of 20 mm to 40 mm. In some embodiments, the polymermodified asphalt coating has a penetration point of 25 mm to 35 mm.

In some embodiments, the polymer modified asphalt coating has aviscosity of 200 cP to 1,000 cP. In some embodiments, the polymermodified asphalt coating has a viscosity of 300 cP to 1,000 cP. In someembodiments, the polymer modified asphalt coating has a viscosity of 400cP to 1,000 cP. In some embodiments, the polymer modified asphaltcoating has a viscosity of 500 cP to 1,000 cP. In some embodiments, thepolymer modified asphalt coating has a viscosity of 600 cP to 1,000 cP.In some embodiments, the polymer modified asphalt coating has aviscosity of 700 cP to 1,000 cP. In some embodiments, the polymermodified asphalt coating has a viscosity of 800 cP to 1,000 cP. In someembodiments, the polymer modified asphalt coating has a viscosity of 900cP to 1,000 cP.

In some embodiments, the polymer modified asphalt coating has aviscosity of 200 cP to 1,000 cP. In some embodiments, the polymermodified asphalt coating has a viscosity of 200 cP to 900 cP. In someembodiments, the polymer modified asphalt coating has a viscosity of 200cP to 800 cP. In some embodiments, the polymer modified asphalt coatinghas a viscosity of 200 cP to 700 cP. In some embodiments, the polymermodified asphalt coating has a viscosity of 200 cP to 600 cP. In someembodiments, the polymer modified asphalt coating has a viscosity of 200cP to 500 cP. In some embodiments, the polymer modified asphalt coatinghas a viscosity of 200 cP to 400 cP. In some embodiments, the polymermodified asphalt coating has a viscosity of 200 cP to 300 cP.

In some embodiments, the polymer modified asphalt coating has aviscosity of 300 cP to 900 cP. In some embodiments, the polymer modifiedasphalt coating has a viscosity of 400 cP to 800 cP. In someembodiments, the polymer modified asphalt coating has a viscosity of 500cP to 700 cP.

In some embodiments, the mixture of: the ASW powder, the AC powder, orany combination thereof; and the asphalt coating is heated to form aheated mixture. Non-limiting examples of heaters that can be used toform the heated mixture include heat exchangers, horizontal or verticaldirect fired heaters, horizontal or vertical indirect-fired (convection)heaters, fire-tube heaters, fluid tube heaters or any combinationthereof. Non-limiting examples of heat exchangers include shell and tubeheat exchangers with asphalt on either the shell or tube side, plateheat exchangers, heat recovery heat exchangers or any combinationthereof.

In some embodiments, the mixture of: the ASW powder, the AC powder, orany combination thereof; and the asphalt coating is heated using atleast one heater to form the heated mixture. In some embodiments, themixture of: the ASW powder, the AC powder, or any combination thereof;and the asphalt coating is heated using a plurality of heaters to formthe heated mixture. In some embodiments, the mixture of: the ASW powder,the AC powder, or any combination thereof and the asphalt coating isheated using at least two heaters to form the heated mixture. In someembodiments, the mixture of: the ASW powder, the AC powder, or anycombination thereof; and the asphalt coating is heated using at leastthree heaters to form the heated mixture. In some embodiments, themixture of: the ASW powder, the AC powder, or any combination thereof;and the asphalt coating is heated using at least four heaters to formthe heated mixture. In some embodiments, the mixture of: the ASW powder,the AC powder, or any combination thereof; and the asphalt coating isheated using at least five heaters to form the heated mixture. In someembodiments, the mixture of: the ASW powder, the AC powder, or anycombination thereof; and the asphalt coating is heated using at leastten heaters to form the heated mixture. In some embodiments, the mixtureof: the ASW powder, the AC powder, or any combination thereof; and theasphalt coating is heated using at least twenty heaters to form theheated mixture. In some embodiments, the mixture of: the ASW powder, theAC powder, or any combination thereof; and the asphalt coating is heatedin at least fifty heaters to form the heated mixture. In someembodiments, the mixture of: the ASW powder, the AC powder, or anycombination thereof; and the asphalt coating is heated using at leastone-hundred heaters to form the heated mixture. In some embodiments, themixture of: the ASW powder, the AC powder, or any combination thereof;and the asphalt coating is heated using one heater to form the heatedmixture. In some embodiments, the mixture of: the ASW powder, the ACpowder, or any combination thereof; and the asphalt coating is heatedusing two heaters to form the heated mixture. In some embodiments, themixture of: the ASW powder, the AC powder, or any combination thereof;and the asphalt coating is heated using three heaters to form the heatedmixture. In some embodiments, the mixture of: the ASW powder, the ACpowder, or any combination thereof; and the asphalt coating is heatedusing four heaters to form the heated mixture. In some embodiments, themixture of: the ASW powder, the AC powder, or any combination thereof;and the asphalt coating is heated using five heaters to form the heatedmixture. In some embodiments, the mixture of: the ASW powder, the ACpowder, or any combination thereof; and the asphalt coating is heatedusing ten heaters to form the heated mixture. In some embodiments, themixture of: the ASW powder, the AC powder, or any combination thereof;and the asphalt coating is heated using twenty heaters to form theheated mixture. In some embodiments, the mixture of: the ASW powder, theAC powder, or any combination thereof; and the asphalt coating is heatedusing fifty heaters to form the heated mixture. In some embodiments, themixture of: the ASW powder, the AC powder, or any combination thereof;and the asphalt coating is heated using one-hundred heaters to form theheated mixture.

In some embodiments, the heated mixture has a temperature in a range of400° F. to 500° F. In some embodiments, the heated mixture has atemperature in a range of 410° F. to 500° F. In some embodiments, theheated mixture has a temperature in a range of 410° F. to 500° F. Insome embodiments, the heated mixture has a temperature in a range of420° F. to 500° F. In some embodiments, the heated mixture has atemperature in a range of 430° F. to 500° F. In some embodiments, theheated mixture has a temperature in a range of 440° F. to 500° F. Insome embodiments, the heated mixture has a temperature in a range of450° F. to 500° F. In some embodiments, the heated mixture has atemperature in a range of 460° F. to 500° F. In some embodiments, theheated mixture has a temperature in a range of 470° F. to 500° F. Insome embodiments, the heated mixture has a temperature in a range of480° F. to 500° F. In some embodiments, the heated mixture has atemperature in a range of 490° F. to 500° F.

In some embodiments, the heated mixture has a temperature in a range of400° F. to 490° F. In some embodiments, the heated mixture has atemperature in a range of 400° F. to 480° F. In some embodiments, theheated mixture has a temperature in a range of 400° F. to 470° F. Insome embodiments, the heated mixture has a temperature in a range of400° F. to 460° F. In some embodiments, the heated mixture has atemperature in a range of 400° F. to 450° F. In some embodiments, theheated mixture has a temperature in a range of 400° F. to 440° F. Insome embodiments, the heated mixture has a temperature in a range of400° F. to 430° F. In some embodiments, the heated mixture has atemperature in a range of 400° F. to 420° F. In some embodiments, theheated mixture has a temperature in a range of 400° F. to 410° F.

In some embodiments, the heated mixture has a temperature in a range of410° F. to 490° F. In some embodiments, the heated mixture has atemperature in a range of 420° F. to 480° F. In some embodiments, theheated mixture has a temperature in a range of 430° F. to 470° F. Insome embodiments, the heated mixture has a temperature in a range of440° F. to 460° F.

In some embodiments, the mixture of: the ASW powder, the AC powder, orany combination thereof; and the asphalt coating is homogenized, usingat least one homogenizer, before heating, after heating, or anycombination thereof. In some embodiments, the mixture of: the ASWpowder, the AC powder, or any combination thereof; and the asphaltcoating is homogenized, using a plurality of homogenizers, beforeheating, after heating, or any combination thereof.

In some embodiments, the mixture of: the ASW powder, the AC powder, orany combination thereof; and the asphalt coating is homogenized, usingat least two homogenizers, before heating, after heating, or anycombination thereof. In some embodiments, the mixture of: the ASWpowder, the AC powder, or any combination thereof; and the asphaltcoating is homogenized, using at least three homogenizers, beforeheating, after heating, or any combination thereof. In some embodiments,the mixture of: the ASW powder, the AC powder, or any combinationthereof; and the asphalt coating is homogenized, using at least fourhomogenizers, before heating, after heating, or any combination thereof.In some embodiments, the mixture of the mixture of: the ASW powder, theAC powder, or any combination thereof; and the asphalt coating ishomogenized, using at least five homogenizers, before heating, afterheating, or any combination thereof. In some embodiments, the mixtureof: the ASW powder, the AC powder, or any combination thereof; and theasphalt coating is homogenized, using at least ten homogenizers, beforeheating, after heating, or any combination thereof. In some embodiments,the mixture of: the ASW powder, the AC powder, or any combinationthereof; and the asphalt coating is homogenized, using at least twentyhomogenizers, before heating, after heating, or any combination thereof.In some embodiments, the mixture of: the ASW powder, the AC powder, orany combination thereof; and the asphalt coating is homogenized, usingat least fifty homogenizers, before heating, after heating, or anycombination thereof. In some embodiments, the mixture of: the ASWpowder, the AC powder, or any combination thereof; and the asphaltcoating is homogenized, using at least one-hundred homogenizers, beforeheating, after heating, or any combination thereof.

In some embodiments, the mixture of: the ASW powder, the AC powder, orany combination thereof; and the asphalt coating is homogenized, usingone homogenizer, before heating, after heating, or any combinationthereof. In some embodiments the mixture of: the ASW powder, the ACpowder, or any combination thereof; and the asphalt coating ishomogenized, using two homogenizers, before heating, after heating, orany combination thereof. In some embodiments, the mixture of: the ASWpowder, the AC powder, or any combination thereof; and the asphaltcoating is homogenized, using three homogenizers, before heating, afterheating, or any combination thereof. In some embodiments, the mixtureof: the ASW powder, the AC powder, or any combination thereof; and theasphalt coating is homogenized, using four homogenizers, before heating,after heating, or any combination thereof. In some embodiments, themixture of: the ASW powder, the AC powder, or any combination thereof;and the asphalt coating is homogenized, using five homogenizers, beforeheating, after heating, or any combination thereof. In some embodiments,the mixture of: the ASW powder, the AC powder, or any combinationthereof and the asphalt coating is homogenized, using ten homogenizers,before heating, after heating, or any combination thereof. In someembodiments, the mixture of: the ASW powder, the AC powder, or anycombination thereof; and the asphalt coating is homogenized, usingtwenty homogenizers, before heating, after heating, or any combinationthereof. In some embodiments, the mixture of: the ASW powder, the ACpowder, or any combination thereof; and the asphalt coating ishomogenized, using fifty homogenizers, before heating, after heating, orany combination thereof. In some embodiments, the mixture of: the ASWpowder, the AC powder, or any combination thereof; and the asphaltcoating is homogenized, using one-hundred homogenizers, before heating,after heating, or any combination thereof.

In some embodiments, any number of heaters may be located upstream fromany number of homogenizers, downstream from any number of homogenizers,or any combination thereof.

In some embodiments, the heated mixture of: the ASW powder, the ACpowder, or any combination thereof and the asphalt coating is conveyedto at least one second mixer. In some embodiments, the at least onesecond mixer is of the same type as the at least one first mixer. Insome embodiments, the at least one second mixer is of a different typethan the at least one first mixer Non-limiting examples of mixers thatcan be used as the at least one second mixer include, vertically orhorizontally agitated tanks, high or low shear tubular mixers,horizontal paddle mixers, screw transport mixers, continuous high shearmixers, progressive cavity mixing pumps or any combination thereof.

In some embodiments, the at least one second mixer comprises a pluralityof second mixers. In some embodiments, the at least one second mixercomprises at least two second mixers. In some embodiments, the at leastone second mixer comprises at least three second mixers. In someembodiments, the at least one second mixer comprises at least foursecond mixers. In some embodiments, the at least one second mixercomprises at least five second mixers. In some embodiments, the at leastone second mixer comprises at least ten second mixers. In someembodiments, the at least one second mixer comprises at least twentysecond mixers. In some embodiments, the at least one second mixercomprises at least fifty second mixers. In some embodiments, the atleast one second mixer comprises at least one-hundred second mixers.

In some embodiments, the at least one second mixer consists of a singlesecond mixer. In some embodiments, the at least one second mixerconsists of two second mixers. In some embodiments, the at least onesecond mixer consists of three second mixers. In some embodiments, theat least one second mixer consists of four second mixers. In someembodiments, the at least one second mixer consists of five secondmixers. In some embodiments, the at least one second mixer consists often second mixers. In some embodiments, the at least one second mixerconsists of twenty second mixers. In some embodiments, the at least onesecond mixer consists of fifty second mixers. In some embodiments, theat least one second mixer consists of one-hundred second mixers.

In some embodiments, a sufficient amount of at least one filler materialis mixed with the heated mixture in the at least one second mixer toobtain an ASW powder filled coating, an AC powder filled coating, orcombination thereof that comprises 30 wt % to 50 wt % asphalt based onthe total weight of the ASW powder filled coating, the AC powder filledcoating, or combination thereof. In some embodiments, a sufficientamount of at least one filler material is mixed with the heated mixturein the at least one second mixer to obtain a ASW powder filled coating,an AC powder filled coating, or combination thereof that comprises 35 wt% to 50 wt % asphalt based on the total weight of the ASW powder filledcoating, the AC powder filled coating, or combination thereof. In someembodiments, a sufficient amount of at least one filler material ismixed with the heated mixture in the at least one second mixer to obtainan ASW powder filled coating, an AC powder filled coating, orcombination thereof that comprises 40 wt % to 50 wt % asphalt based onthe total weight of the ASW powder filled coating, the AC powder filledcoating, or combination thereof. In some embodiments, a sufficientamount of at least one filler material is mixed with the heated mixturein the at least one second mixer to obtain an ASW powder filled coating,an AC powder filled coating, or combination thereof that comprises 45 wt% to 50 wt % asphalt based on the total weight of the ASW powder filledcoating, the AC powder filled coating, or combination thereof.

In some embodiments, a sufficient amount of at least one filler materialis mixed with the heated mixture in the at least one second mixer toobtain an ASW powder filled coating, an AC powder filled coating, orcombination thereof that comprises 30 wt % to 45 wt % asphalt based onthe total weight of the ASW powder filled coating, the AC powder filledcoating, or combination thereof. In some embodiments, a sufficientamount of at least one filler material is mixed with the heated mixturein the at least one second mixer to an ASW powder filled coating, an ACpowder filled coating, or combination thereof that comprises 30 wt % to40 wt % asphalt based on the total weight of the ASW powder filledcoating, the AC powder filled coating, or combination thereof. In someembodiments, a sufficient amount of at least one filler material ismixed with the heated mixture in the at least one second mixer to obtainan ASW powder filled coating, an AC powder filled coating, orcombination thereof that comprises 30 wt % to 35 wt % asphalt based onthe total weight of the ASW powder filled coating, the AC powder filledcoating, or combination thereof.

In some embodiments, a sufficient amount of at least one filler materialis mixed with the heated mixture in the at least one second mixer toobtain an ASW powder filled coating, an AC powder filled coating, orcombination thereof that comprises 35 wt % to 45 wt % asphalt based onthe total weight of the ASW or AC powder filled coating.

In some embodiments, a sufficient amount of at least one filler materialis mixed with the heated mixture in the at least one second mixer toobtain an ASW powder filled coating, an AC powder filled coating, orcombination thereof that comprises 50 wt % to 70 wt % of: limestonepowder, granules, impurities, and the at least one filler material basedon the total weight of the ASW powder filled coating or AC powder filledcoating. In some embodiments, a sufficient amount of at least one fillermaterial is mixed with the heated mixture in the at least one secondmixer to obtain an ASW powder filled coating, an AC powder filledcoating, or combination thereof that comprises 50 wt % to 65 wt % of:limestone powder, granules, impurities, and the at least one fillermaterial based on the total weight of the ASW powder filled coating orAC powder filled coating. In some embodiments, a sufficient amount of atleast one filler material is mixed with the heated mixture in the atleast one second mixer to obtain an ASW powder filled coating, an ACpowder filled coating, or combination thereof that comprises 50 wt % to60 wt % of: limestone powder, granules, impurities, and the at least onefiller material based on the total weight of the ASW powder filledcoating or AC powder filled coating. In some embodiments, a sufficientamount of at least one filler material is mixed with the heated mixturein the at least one second mixer to obtain an ASW powder filled coating,an AC powder filled coating, or combination thereof that comprises 50 wt% to 55 wt % of: limestone powder, granules, impurities, and the atleast one filler material based on the total weight of the ASW powderfilled coating or AC powder filled coating.

In some embodiments, a sufficient amount of at least one filler materialis mixed with the heated mixture in the at least one second mixer toobtain an ASW powder filled coating, an AC powder filled coating, orcombination thereof that comprises 55 wt % to 70 wt % of: limestonepowder, granules, impurities, and the at least one filler material basedon the total weight of the ASW powder filled coating or AC powder filledcoating. In some embodiments, a sufficient amount of at least one fillermaterial is mixed with the heated mixture in the at least one secondmixer to obtain an ASW powder filled coating, an AC powder filledcoating, or combination thereof that comprises 60 wt % to 70 wt % of:limestone powder, granules, impurities, and the at least one fillermaterial based on the total weight of the ASW powder filled coating orAC powder filled coating. In some embodiments, a sufficient amount of atleast one filler material is mixed with the heated mixture in the atleast one second mixer to obtain an ASW powder filled coating, an ACpowder filled coating, or combination thereof that comprises 65 wt % to70 wt % of: limestone powder, granules, impurities, and the at least onefiller material based on the total weight of the ASW powder filledcoating, the AC powder filled coating, or combination thereof.

In some embodiments, a sufficient amount of at least one filler materialis mixed with the heated mixture in the at least one second mixer toobtain an ASW powder filled coating, an AC powder filled coating, orcombination thereof that comprises 55 wt % to 60 wt % of: limestonepowder, granules, impurities, and the at least one filler material basedon the total weight of the ASW powder filled coating or AC powder filledcoating.

In some embodiments, the at least one filler material is subjected to adust-collection step. In some embodiments, the at least one fillermaterial is heated before the at least one filler material is added theat least one second mixer.

A non-limiting example of the at least one filler material is limestonepowder. Other non-limiting examples of the at least one filler materialinclude flyash, fiberglass particles, stone dust, and combinationsthereof.

In some embodiments, the weight percentage of asphalt in the ASW powderfilled coating, based on the total weight of the ASW powder filledcoating, is the same as a weight percentage of asphalt in a powderfilled coating that does not contain any ASW. In some embodiments, asoftening point of the ASW powder filled coating is the same as asoftening point of a powder filled coating that does not contain anyASW. In some embodiments, a penetration point of the ASW powder filledcoating is the same as a penetration point of a powder filled coatingthat does not contain any ASW.

In some embodiments, the ASW powder filled coating comprises 1 wt % to40 wt % of the ASW powder based on the total weight of the ASW powderfilled coating. In some embodiments, the ASW powder filled coatingcomprises 5 wt % to 40 wt % of the ASW powder based on the total weightof the ASW powder filled coating. In some embodiments, the ASW powderfilled coating comprises 10 wt % to 40 wt % of the ASW powder based onthe total weight of the ASW powder filled coating. In some embodiments,the ASW powder filled coating comprises 20 wt % to 40 wt % of the ASWpowder based on the total weight of the ASW powder filled coating. Insome embodiments, the ASW powder filled coating comprises 30 wt % to 40wt % of the ASW powder based on the total weight of the ASW powderfilled coating.

In some embodiments, the ASW powder filled coating comprises 1 wt % to30 wt % of the ASW powder based on the total weight of the ASW powderfilled coating. In some embodiments, the ASW powder filled coatingcomprises 1 wt % to 20 wt % of the ASW powder based on the total weightof the ASW powder filled coating. In some embodiments, the ASW powderfilled coating comprises 1 wt % to 10 wt % of the ASW powder based onthe total weight of the ASW powder filled coating. In some embodiments,the ASW powder filled coating comprises 1 wt % to 5 wt % of the ASWpowder based on the total weight of the ASW powder filled coating.

In some embodiments, the ASW powder filled coating comprises 5 wt % to40 wt % of the ASW powder based on the total weight of the ASW powderfilled coating. In some embodiments, the ASW powder filled coatingcomprises 10 wt % to 30 wt % of the ASW powder based on the total weightof the ASW powder filled coating. In some embodiments, the ASW powderfilled coating comprises 15 wt % to 20 wt % of the ASW powder based onthe total weight of the ASW powder filled coating. In some embodiments,the ASW powder filled coating comprises 20 wt % to 25 wt % of the ASWpowder based on the total weight of the ASW powder filled coating.

In some embodiments where the at least one filler material compriseslimestone powder, the ASW powder filled coating, the AC powder filledcoating, or combination thereof can comprise 50% to 70% of: limestonepowder, granules, and impurities based on the total weight of the ASWpowder filled coating, the AC powder filled coating, or combinationthereof. In some embodiments where the at least one filler materialcomprises limestone powder, the ASW powder filled coating, the AC powderfilled coating, or combination thereof can comprise 55% to 70% of:limestone powder, granules, and impurities based on the total weight ofthe ASW powder filled coating, the AC powder filled coating, orcombination thereof. In some embodiments where the at least one fillermaterial comprises limestone powder, the ASW powder filled coating, theAC powder filled coating, or combination thereof can comprise 60% to 70%of: limestone powder, granules, and impurities based on the total weightof the ASW powder filled coating, the AC powder filled coating, orcombination thereof. In some embodiments where the at least one fillermaterial comprises limestone powder, the ASW powder filled coating, theAC powder filled coating, or combination thereof can comprise 65% to 70%of: limestone powder, granules, and impurities based on the total weightof the ASW powder filled coating, the AC powder filled coating, orcombination thereof.

In some embodiments where the at least one filler material compriseslimestone powder, the ASW powder filled coating, the AC powder filledcoating, or combination thereof can comprise 55% to 70% of: limestonepowder, granules, and impurities based on the total weight of the ASWpowder filled coating, the AC powder filled coating, or combinationthereof. In some embodiments where the at least one filler materialcomprises limestone powder, the ASW powder filled coating, the AC powderfilled coating, or combination thereof can comprise 60% to 70% of:limestone powder, granules, and impurities based on the total weight ofthe ASW powder filled coating, the AC powder filled coating, orcombination thereof. In some embodiments where the at least one fillermaterial comprises limestone powder, the ASW powder filled coating, theAC powder filled coating, or combination thereof can comprise 65% to 70%of: limestone powder, granules, and impurities based on the total weightof the ASW powder filled coating, the AC powder filled coating, orcombination thereof.

In some embodiments where the at least one filler material compriseslimestone powder, the ASW powder filled coating, the AC powder filledcoating, or combination thereof can comprise 55% to 60% of: limestonepowder, granules, and impurities based on the total weight of the ASWpowder filled coating, the AC powder filled coating, or combinationthereof.

In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof may be homogenized. In some embodiments,any number of homogenizers, heaters, or mixers may be added at any stageof the method without deviating from the scope of the presentdisclosure.

In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 100 cP to 20,000 cP.In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 500 cP to 20,000 cP.In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 1,000 cP to 20,000cP. In some embodiments, the ASW powder filled coating, the AC powderfilled coating, or combination thereof has a viscosity of 5,000 cP to20,000 cP. In some embodiments, the ASW powder filled coating, the ACpowder filled coating, or combination thereof has a viscosity of 10,000cP to 20,000 cP. In some embodiments, the ASW powder filled coating, theAC powder filled coating, or combination thereof has a viscosity of15,000 cP to 20,000 cP.

In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 100 cP to 15,000 cP.In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 100 cP to 10,000 cP.In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 100 cP to 5,000 cP.In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 100 cP to 1,000 cP.In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 100 cP to 500 cP.

In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 500 cP to 15,000 cP.In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof has a viscosity of 1,000 cP to 10,000cP. In some embodiments, the ASW powder filled coating, the AC powderfilled coating, or combination thereof has a viscosity of 5,000 cP.

In some embodiments, the ASW powder filled coating, the AC powder filledcoating, or combination thereof is applied to a fiberglass mat to form acoated fiberglass mat. In some embodiments, at least one of granules orsand are applied to the coated fiberglass mat to form an asphaltshingle.

FIG. 3 depicts an exemplary non-limiting method according to someembodiments of the present disclosure showing a continuous process ofproducing an ASW powder filled coating, the AC powder filled coating, orcombination thereof as described herein. The non-limiting example ofFIG. 3 may include the following steps detailed below.

Sufficient grinding and screening steps (not shown) may be performed onASW to result in ASW powder 301 having the average particle sizedescribed herein. In some embodiments, an AC powder 301 can be obtained.In some embodiments a combination 301 of ASW powder and AC powder can beobtained.

A specified amount of the ASW powder, the AC powder, or combinationthereof 301 described herein, is combined with a specified amount ofasphalt coating, described herein in tank 302 and fed into first mixers303 a and 303 b, where a sufficient amount of shear is applied so as toform a mixture of: ASW powder, AC powder, or combination thereof; andasphalt coating, as described herein. While the embodiment of FIG. 3depicts two first mixers 303 a and 303 b, in some embodiments, a singlefirst mixer can be used.

Heat exchanger 304 heats the mixture of: ASW powder, AC powder, orcombination thereof; and asphalt coating to a specified temperature soas to form a heated mixture of the ASW or AC powder and the asphaltcoating, as described herein. While the embodiment of FIG. 3 depictsheat exchanger 304, any heater or combination of heaters describedherein can be used.

A specified amount of the heated mixture of: the ASW powder, AC powder,or combination thereof; and the asphalt coating can be fed into storagetank 305. The storage tank 305 may be in thermal communication with aheater, such as heat exchanger 306.

A specified amount of the heated mixture of the ASW powder, AC powder,or combination thereof; and the asphalt coating can be conveyed fromstorage tank 305 into second mixer 307 where the at least one fillermaterial 308, described herein, is introduced to the heated mixture ofthe ASW powder, AC powder, or combination thereof; and the asphaltcoating. A sufficient amount of shear is applied to form the ASW powderfilled coating, AC powder filled coating, or combination thereof.

The ASW powder filled coating, the AC powder filled coating, orcombination thereof can be fed into surge tank 309 where the ASW powderfilled coating, the AC powder filled coating, or combination thereof canbe stirred until homogenous. The ASW or AC powder filled coating can betransported to coater 310 where, in some embodiments, the ASW powderfilled coating, the AC powder filled coating, or combination thereof isapplied to a fiberglass mat to form a coated fiberglass mat; and where,in some embodiments, at least one of granules or sand are applied to thecoated fiberglass mat to form an asphalt shingle.

Additional Exemplary Embodiments

In some embodiments, any of the briquetting steps described herein, anyof the ASW powder formation steps described herein, any of the ASWpowder filled coating formation steps described herein, or anycombination thereof may be combined without departing from the scope ofthe present disclosure. In addition, in any of the aforementionedembodiments, at least one: of AC powder, ASW powder, AC powder filledcoatings, ASW powder filled coatings, combinations thereof, orbriquettes comprising any of the foregoing may be used in any stepdescribed herein without departing from the scope of the presentdisclosure.

At least some non-limiting aspects of the present disclosure will now bedescribed with reference to the following numbered embodimentshereinafter designated as [E1, E2, E3, E4 . . . ]

E1: A method comprising:

-   -   obtaining asphalt shingle waste (ASW),        -   wherein the ASW comprises:            -   asphalt,            -   limestone,            -   granules, and            -   impurities;    -   grinding the ASW to form ground ASW;    -   screening the ground ASW with a rotary screener,        -   wherein the screening of the ground ASW with the rotary            screener results in:            -   a first set of ASW particles,                -   wherein the first set of ASW particles has an                    average particle size of 425 microns to 6350                    microns, and            -   a second set of ASW particles,                -   wherein the second set of ASW particles has an                    average particle size of 2 microns to 425 microns;    -   removing at least some of the granules from at least one of the        first set of ASW particles, the second set of ASW particles, or        a combination thereof with at least one granule liberator;    -   grinding the first set of ASW particles,        -   wherein the grinding of the first set of ASW particles            results in a third set of ASW particles,            -   wherein the third set of ASW particles has an average                particle size of 2 microns to 425 microns;    -   separating the second and third sets of ASW particles using an        air separator,        -   wherein the separating using the air separator results in:            -   a fourth set of ASW particles,                -   wherein the fourth set of ASW particles have an                    average particle size of 250 microns to 450 microns;                    and            -   a fifth set of ASW particles,                -   wherein the fifth set of ASW particles have an                    average particle size of 2 microns to 250 microns;        -   grinding the fourth set of ASW particles;            -   wherein the grinding of the fourth set of ASW particles                results in a sixth set of ASW particles,                -   wherein the sixth set of ASW particles have an                    average particle size of 2 microns to 250 microns;                -   wherein each of the fifth set of ASW particles and                    the sixth set of ASW particles is an ASW powder                    having the following composition:                -    5 wt % to 40 wt % asphalt based on a total weight                    of the ASW powder, and                -    60 wt % to 95 wt % of limestone, granules, and                    impurities based on the total weight of the ASW                    powder,    -   wherein the method does not comprise a wet extraction step.

E2: The method of E1, wherein the rotary screener is a trommel screener.

E3: The method of E1, E2, or any combination thereof, wherein the methoddoes not comprise a grinding step after the step of grinding the fourthset of ASW particles.

E4: The method of E1, E2, E3 or any combination thereof, wherein themethod does not comprise any grinding steps other than the steps of:grinding the ASW, grinding the first set of ASW particles, and grindingthe fourth set of ASW particles.

E5: The method of E1, E2, E3, E4 or any combination thereof, wherein theimpurities comprise least one of: fiberglass mat sand, fines, markerpaint, sealant, one or more adhesives, tape, plastic debris, paperdebris, soil, woods, nails, or any combination thereof.

E6: The method of E1, E2, E3, E4, E5, or any combination thereof,wherein the method does not comprise any steps of screening with avibratory screener.

E7: The method of E1, E2, E3, E4, E5, E6, or any combination thereof,wherein the method does not comprise any steps of screening with ascreening device that comprises at least one ball tray.

E8: The method of E1, E2, E3, E4, E5, E6, E7 or any combination thereof,wherein the method does not comprise any steps of screening with asizing shaker.

E9: The method of E1, E2, E3, E4, E5, E6, E7, E8, or any combinationthereof, wherein the method does not comprise a screening step after thestep of separating the second and third sets of ASW particles using theair separator.

E10: The method of E1, E2, E3, E4, E5, E6, E7, E8, E9 or any combinationthereof, wherein the second and third sets of ASW particles are combinedprior to the step of separating the second and third sets of ASWparticles using the air separator.

E11: The method of E1, E2, E3, E4, E5, E6, E7, E8, E9, E10, or anycombination thereof wherein the fifth set of ASW particles and the sixthset of ASW particles are combined to form the ASW powder.

E12: The method of E1, E2, E3, E4, E5, E6, E7, E8, E9, E10, E11, or anycombination thereof, wherein the method further comprises forming theASW powder into a plurality of briquettes.

E13: The method of E12, wherein forming the ASW powder into theplurality of briquettes comprises adding limestone powder to the ASWpowder.

E14: The method of E12, wherein the forming the ASW powder into theplurality of briquettes comprises compressing the ASW powder at apressure sufficient to form the plurality of briquettes.

E15: The method of E14, wherein the pressure sufficient to form theplurality of briquettes ranges from 200 psi to 20,000 psi.

E16: The method of E12, wherein each briquette of the plurality ofbriquettes is an oblate spheroid

E17: The method of E16, wherein each briquette of the plurality ofbriquettes has a first diameter and a second diameter, wherein at leastone of: the first diameter, the second diameter, or any combinationthereof ranges from 0.5 inches to 2 inches.

E18: The method of E1, E2, E3, E4, E5, E6, E7, E8, E9, E10, E11, E12,E13, E14, E15, E16, E17, or any combination thereof, wherein the atleast one granule liberator comprises a rotary impact separator.

E19: The method of E1, E2, E3, E4, E5, E6, E7, E8, E9, E10, E11, E12,E13, E14, E15, E16, E17, E18, or any combination thereof, wherein themethod further comprises using a scalping screen to separate particleshaving an average particle size of 4 microns to 425 microns from theground ASW.

E20: The method of E19, wherein the step of using the scalping screen isperformed between the steps of: grinding the ASW and screening theground ASW.

E21: The method of E1, E2, E3, E4, E5, E6, E7, E8, E9, E10, E11, E12,E13, E14, E15, E16, E17, E18, E19, E20, or any combination thereof,wherein the method comprises deagglomerating the ground ASW using a lumpbreaker.

E22: The method of E21, wherein the step of deagglomerating the groundASW is performed between the steps of: grinding the ASW and screeningthe ground ASW.

E23: A method comprising:

-   -   obtaining asphalt shingle waste (ASW),        -   wherein the ASW comprises:            -   asphalt,            -   limestone,            -   granules, and            -   impurities;    -   grinding the ASW to form ground ASW;    -   screening the ground ASW with a rotary screener,        -   wherein the screening of the ground ASW with the rotary            screener results in:            -   a first set of ASW particles,                -   wherein the first set of ASW particles has an                    average particle size of 425 microns to 6350                    microns, and            -   a second set of ASW particles,                -   wherein the second set of ASW particles has an                    average particle size of 2 microns to 425 microns;    -   removing at least some of the granules from at least one of: the        first set of ASW particles, the second set of ASW particles, or        a combination thereof with a granule liberator;    -   grinding the first set of ASW particles,        -   wherein the grinding of the first set of ASW particles            results in a third set of ASW particles,        -   wherein the third set of ASW particles has an average            particle size of 2 microns to 425 microns;    -   separating the second and third sets of ASW particles using an        air separator,        -   wherein the separating using the air separator results in:            -   a fourth set of ASW particles,                -   wherein the fourth set of ASW particles have an                    average particle size of 250 microns to 450 microns;                    and            -   a fifth set of ASW particles,                -   wherein the fifth set of ASW particles have an                    average particle size of 2 microns to 250 microns;    -   grinding the fourth set of ASW particles;        -   wherein the grinding of the fourth set of ASW particles            results in a sixth set of ASW particles,        -   wherein the sixth set of ASW particles have an average            particle size of 2 microns to 250 microns;        -   wherein each of the fifth set of ASW particles and the sixth            set of ASW particles is an ASW powder having the following            composition:            -   5 wt % to 40 wt % asphalt based on a total weight of the                ASW powder, and            -   60 wt % to 95 wt % of limestone, granules, and                impurities based on the total weight of the ASW powder,    -   forming the ASW powder into a plurality of briquettes;

wherein the method does not comprise a wet extraction step.

E24: The method of E23, wherein forming the ASW powder into theplurality of briquettes comprises adding limestone powder to the ASWpowder.

E25: The method of E23 or E24, wherein the forming the ASW powder intothe plurality of briquettes comprises compressing the ASW powder at apressure sufficient to form the plurality of briquettes.

E26: The method of E25 wherein the pressure sufficient to form theplurality of briquettes ranges from 200 psi to 20,000 psi.

E27: A method comprising:

-   -   obtaining asphalt shingle waste (ASW),        -   wherein the ASW comprises:            -   asphalt,            -   limestone,            -   granules, and            -   impurities;    -   grinding the ASW to form ground ASW;    -   screening the ground ASW with a rotary screener,        -   wherein the screening of the ground ASW with the rotary            screener results in:            -   a first set of ASW particles,                -   wherein the first set of ASW particles has an                    average particle size of 425 microns to 6350                    microns, and            -   a second set of ASW particles,                -   wherein the second set of ASW particles has an                    average particle size of 2 microns to 425 microns;    -   removing at least some of the granules from at least one of: the        first set of ASW particles, the second set of ASW particles, or        a combination thereof with a granule liberator;    -   grinding the first set of ASW particles,        -   wherein the grinding of the first set of ASW particles            results in a third set of ASW particles,        -   wherein the third set of ASW particles has an average            particle size of 2 microns to 425 microns;    -   separating the second and third sets of ASW particles using an        air separator,        -   wherein the separating using the air separator results in:            -   a fourth set of ASW particles,                -   wherein the fourth set of ASW particles have an                    average particle size of 250 microns to 450 microns;                    and            -   a fifth set of ASW particles,                -   wherein the fifth set of ASW particles have an                    average particle size of 2 microns to 250 microns;    -   grinding the fourth set of ASW particles;        -   wherein the grinding of the fourth set of ASW particles            results in a sixth set of ASW particles,        -   wherein the sixth set of ASW particles has an average            particle size of 2 microns to 250 microns;        -   wherein at least one of: the second set of ASW particles,            the third set of ASW particles, the fourth set of ASW            particles, the fifth set of ASW particles, the sixth set of            ASW particles or any combination thereof comprises an ASW            powder having the following composition:            -   5 wt % to 40 wt % asphalt based on a total weight of the                ASW powder, and            -   60 wt % to 95 wt % of limestone, granules, and                impurities based on the total weight of the ASW powder,    -   obtaining the ASW powder from at least one of: the second set of        ASW particles, the third set of ASW particles, the fourth set of        ASW particles, the fifth set of ASW particles, the sixth set of        ASW particles, or any combination thereof,        -   wherein the ASW powder has an average particle size of 2            microns to 425 microns;    -   feeding a sufficient amount of the ASW powder and a sufficient        amount of an asphalt coating into at least one first mixer to        form a mixture of the ASW powder and the asphalt coating;        -   wherein the mixture of the ASW powder and the asphalt            coating has the following composition:            -   0.1 wt % to 50 wt % ASW powder based on a total weight                of the mixture, and            -   50 wt % to 99.9 wt % of the asphalt coating based on a                total weight of the mixture;    -   heating the mixture of the ASW powder and the asphalt coating to        form a heated mixture;        -   wherein the heated mixture has a temperature in a range of            400° F. to 500° F.;    -   conveying the heated mixture of the ASW powder and the asphalt        coating to at least one second mixer;    -   mixing a sufficient amount of at least one filler material with        the heated mixture in the second mixer to obtain an ASW powder        filled coating;        -   wherein the ASW powder filled coating has the following            composition:            -   30 wt % to 50 wt % asphalt based on the total weight of                the ASW powder filled coating, and            -   50 wt % to 70 wt % of: limestone powder, granules,                impurities, and the at least one filler material based                on the total weight of the ASW powder filled coating.

E28: A method comprising:

-   -   obtaining asphalt shingle waste (ASW),        -   wherein the ASW comprises:            -   asphalt,            -   limestone,            -   granules, and            -   impurities;    -   grinding the ASW to form ground ASW;    -   screening the ground ASW with a rotary screener,        -   wherein the screening of the ground ASW with the rotary            screener results in:            -   a first set of ASW particles,                -   wherein the first set of ASW particles has an                    average particle size of 425 microns to 6350                    microns, and            -   a second set of ASW particles,                -   wherein the second set of ASW particles has an                    average particle size of 2 microns to 425 microns;    -   removing at least some of the granules from at least one of: the        first set of ASW particles, the second set of ASW particles, or        a combination thereof with a granule liberator;    -   grinding the first set of ASW particles,        -   wherein the grinding of the first set of ASW particles            results in a third set of ASW particles,        -   wherein the third set of ASW particles has an average            particle size of 2 microns to 425 microns;    -   separating the second and third sets of ASW particles using an        air separator,        -   wherein the separating using the air separator results in:            -   a fourth set of ASW particles,                -   wherein the fourth set of ASW particles have an                    average particle size of 250 microns to 450 microns;                    and            -   a fifth set of ASW particles,                -   wherein the fifth set of ASW particles have an                    average particle size of 2 microns to 250 microns;    -   grinding the fourth set of ASW particles;        -   wherein the grinding of the fourth set of ASW particles            results in a sixth set of ASW particles,        -   wherein the sixth set of ASW particles has an average            particle size of 2 microns to 250 microns;        -   wherein at least one of: the second set of ASW particles,            the third set of ASW particles, the fourth set of ASW            particles, the fifth set of ASW particles, the sixth set of            ASW particles or any combination thereof comprises an ASW            powder having the following composition:            -   5 wt % to 40 wt % asphalt based on a total weight of the                ASW powder, and            -   60 wt % to 95 wt % of limestone, granules, and                impurities based on the total weight of the ASW powder,    -   obtaining the ASW powder from at least one of: the second set of        ASW particles, the third set of ASW particles, the fourth set of        ASW particles, the fifth set of ASW particles, the sixth set of        ASW particles, or any combination thereof,        -   wherein the ASW powder has an average particle size of 2            microns to 425 microns;    -   forming the ASW powder into a plurality of briquettes;    -   feeding a sufficient amount of the plurality of briquettes and a        sufficient amount of an asphalt coating into at least one first        mixer to form a mixture of the ASW powder and the asphalt        coating;        -   wherein the mixture of the ASW powder and the asphalt            coating has the following composition:            -   0.1 wt % to 50 wt % ASW powder based on a total weight                of the mixture, and            -   50 wt % to 99.9 wt % of the asphalt coating based on a                total weight of the mixture;    -   heating the mixture of the ASW powder and the asphalt coating to        form a heated mixture;        -   wherein the heated mixture has a temperature in a range of            400° F. to 500° F.;    -   conveying the heated mixture of the ASW powder and the asphalt        coating to at least one second mixer;    -   mixing a sufficient amount of at least one filler material with        the heated mixture in the second mixer to obtain an ASW powder        filled coating;        -   wherein the ASW powder filled coating has the following            composition:            -   30 wt % to 50 wt % asphalt based on the total weight of                the ASW powder filled coating, and            -   50 wt % to 70 wt % of: limestone powder, granules,                impurities, and the at least one filler material based                on the total weight of the ASW powder filled coating.

E29: A method comprising:

-   -   obtaining asphalt shingle waste (ASW);        -   wherein the ASW comprises:            -   asphalt,            -   limestone powder,            -   granules, and            -   impurities;    -   performing sufficient grinding steps and screening steps on the        ASW to result in ASW powder having an average particle size of 2        microns to 425 microns and the following composition:        -   5 wt % to 40 wt % asphalt based on a total weight of the ASW            powder,        -   60 wt % to 95 wt % limestone powder, granules, and            impurities based on the total weight of the ASW powder;        -   wherein the grinding steps and screening steps do not            comprise wet extraction steps;    -   feeding a sufficient amount of the ASW powder and a sufficient        amount of an asphalt coating into at least one first mixer to        form a mixture of the ASW powder and the asphalt coating;        -   wherein the mixture of the ASW powder and the asphalt            coating has the following composition:            -   0.1 wt % to 50 wt % ASW powder based on a total weight                of the mixture, and            -   50 wt % to 99.9 wt % of the asphalt coating based on a                total weight of the mixture;    -   heating the mixture of the ASW powder and the asphalt coating to        form a heated mixture;        -   wherein the heated mixture has a temperature in a range of            400° F. to 500° F.;    -   conveying the heated mixture of the ASW powder and the asphalt        coating to at least one second mixer;    -   mixing a sufficient amount of at least one filler material with        the heated mixture in the second mixer to obtain an ASW powder        filled coating;        -   wherein the ASW powder filled coating has the following            composition:            -   30 wt % to 50 wt % asphalt based on the total weight of                the ASW powder filled coating, and            -   50 wt % to 70 wt % of: the limestone powder, the                granules, the impurities, and the at least one filler                material based on the total weight of the ASW powder                filled coating.

E30: The method of E29, wherein the impurities comprise at least one of:fiberglass mat sand, fines, marker paint, sealant, one or moreadhesives, tape, plastic debris, paper debris, soil, woods, nails, orany combination thereof.

E31: The method of E29 or E30, wherein the at least one filler materialis limestone powder; and wherein the ASW powder filled coating has thefollowing composition:

-   -   30% to 50% asphalt based on the total weight of the ASW powder        filled coating, and    -   50% to 70% of: limestone powder, granules, and impurities based        on the total weight of the ASW powder filled coating.

E32: the method of E29, E30, E31, or any combination thereof furthercomprising applying the ASW powder filled coating to a fiberglass mat toform a coated fiberglass mat.

E33: the method of E32, further comprising applying at least one ofgranules or sand to the coated fiberglass mat to form an asphaltshingle.

E34: the method of E29, E30, E31, E32, E33, or any combination thereof,wherein the ASW consists essentially of:

-   -   asphalt,    -   limestone powder,    -   granules, and    -   impurities.

E35: the method of E29, E30, E31, E32, E33, E34, or any combinationthereof, wherein the ASW powder has the following composition:

-   -   25 wt % to 30 wt % asphalt based on a total weight of the ASW        powder;    -   70 wt % to 75 wt % limestone powder, granules, and impurities        based on the total weight of the ASW powder.

E36: the method of E29, E30, E31, E32, E33, E34, E35, or any combinationthereof, wherein the asphalt coating comprises at least one of: oxidizedasphalt coating, polymer modified asphalt coating, or mixtures thereof.

E37: the method of E29, E30, E31, E32, E33, E34, E35, E36, or anycombination thereof, wherein the polymer modified asphalt coating ispoly(styrene-butadiene-styrene) (SBS) modified asphalt coating, apoly(styrene-ethylene/butylene-styrene) (SEBS) modified asphalt coating,an atactic polypropylene (APP) modified asphalt coating, an isotacticpolypropylene (IPP) modified asphalt coating, or any mixture thereof.

E38: the method of E29, E30, E31, E32, E33, E34, E35, E36, E37, or anycombination thereof, wherein the weight percentage of asphalt in the ASWpowder filled coating, based on the total weight of the ASW powderfilled coating, is the same as a weight percentage of asphalt in apowder filled coating that does not contain any ASW.

E39: the method of E29, E30, E31, E32, E33, E34, E35, E36, E37, E38, orany combination thereof, wherein the mixture of the ASW powder and theasphalt coating is not subjected to grinding or screening steps.

E40: the method of E29, E30, E31, E32, E33, E34, E35, E36, E37, E38,E39, or any combination thereof, wherein the ASW powder filled coatingcomprises 1 wt % to 40 wt % of the ASW powder based on the total weightof the ASW powder filled coating.

E41: the method of E29, E30, E31, E32, E33, E34, E35, E36, E37, E38,E39, E40 or any combination thereof, wherein the method furthercomprises, after performing sufficient grinding steps and screeningsteps on the ASW to result in the ASW powder, forming the ASW powderinto a plurality of briquettes.

E42: the method of E41, wherein the step of forming the ASW powder intothe plurality of briquettes comprises adding limestone powder to the ASWpowder.

E43: The method of E41 or E42 wherein the step of forming the ASW powderinto the plurality of briquettes comprises compressing the ASW powder ata pressure sufficient to form the plurality of briquettes.

E44: The method of E41, E42, E43, or any combination thereof wherein thepressure sufficient to form the plurality of briquettes ranges from 200psi to 20,000 psi.

E45: The method of E41, E42, E43, E44 or any combination thereof whereinduring the step of feeding the sufficient amount of the ASW powder andthe sufficient amount of an asphalt coating into at the least one firstmixer, at least a portion of the ASW powder takes the form of aplurality of briquettes.

E46: The method of E29, E30, E31, E32, E33, E34, E35, E36, E37, E38,E39, E40, E41, E42, E43, E44, E45, or any combination thereof, whereinthe ASW powder filled coating has a viscosity of 100 cP to 20,000 cP.

E47: A method comprising:

-   -   obtaining asphalt containing (AC) powder;        -   wherein the AC powder has an average particle size of 2            microns to 425 microns;        -   wherein the AC powder comprises ASW powder;        -   wherein the AC powder has the following composition:            -   5 wt % to 40 wt % asphalt based on a total weight of the                AC powder,            -   60 wt % to 95 wt % limestone powder, granules, and                impurities based on the total weight of the AC powder;    -   feeding a sufficient amount of the AC powder and a sufficient        amount of an asphalt coating into at least one first mixer to        form a mixture of the AC powder and the asphalt coating;        -   wherein the mixture of the AC powder and the asphalt coating            has the following composition:            -   0.1 wt % to 50 wt % of AC powder based on a total weight                of the mixture, and            -   50 wt % to 99.9 wt % of the asphalt coating based on a                total weight of the mixture;    -   heating the mixture of the AC powder and the asphalt coating to        form a heated mixture;        -   wherein the heated mixture has a temperature in a range of            400° F. to 500° F.;    -   conveying the heated mixture of the AC powder and the asphalt        coating to at least one second mixer;    -   mixing a sufficient amount of at least one filler material with        the heated mixture in the second mixer to obtain an AC powder        filled coating;        -   wherein the AC powder filled coating has the following            composition:            -   30 wt % to 50 wt % asphalt based on the total weight of                the AC powder filled coating, and            -   50 wt % to 70 wt % of: limestone powder, granules,                impurities, and the at least one filler material based                on the total weight of the AC powder filled coating.

E48: The method of E47, wherein the AC powder filled coating has aviscosity of 100 cP to 20,000 cP.

E49: A method comprising:

-   -   obtaining a plurality of briquettes,        -   wherein each briquette of the plurality of briquettes            comprises asphalt containing (AC) powder, asphalt shingle            waste (ASW) powder, or any combination thereof;        -   wherein the AC powder, the ASW powder, or combination            thereof has an average particle size of 2 microns to 425            microns and the following composition:            -   5 wt % to 40 wt % asphalt based on a total weight of the                AC powder, the ASW powder, or any combination thereof,            -   60 wt % to 95 wt % limestone powder, granules, and                impurities based on the total weight of the AC powder,                the ASW powder, or any combination thereof;    -   feeding a sufficient amount of the briquettes and a sufficient        amount of an asphalt coating into at least one first mixer to        form a mixture of: the AC powder, the ASW powder, or combination        thereof; and the asphalt coating;        -   wherein the mixture of: the AC powder, the ASW powder, or            combination thereof; and the asphalt coating has the            following composition:            -   0.1 wt % to 50 wt % of the AC powder, the ASW powder, or                combination thereof based on a total weight of the                mixture; and            -   50 wt % to 99.9 wt % of the asphalt coating based on a                total weight of the mixture;    -   heating the mixture of: the AC powder, the ASW powder, or        combination thereof; and the asphalt coating to form a heated        mixture;        -   wherein the heated mixture has a temperature in a range of            400° F. to 500° F.;    -   conveying the heated mixture of the AC powder, the ASW powder,        or combination thereof and the asphalt coating to at least one        second mixer;    -   mixing a sufficient amount of at least one filler material with        the heated mixture in the second mixer to obtain an AC powder        filled coating, an ASW powder filled coating or combination        thereof;        -   wherein the AC powder filled coating, the ASW powder filled            coating, or combination thereof has the following            composition:            -   30 wt % to 50 wt % asphalt based on the total weight of                the AC powder filled coating, the ASW powder filled                coating, or combination thereof, and            -   50 wt % to 70 wt % of: limestone powder, granules,                impurities, and the at least one filler material based                on the total weight of the AC powder filled coating, the                ASW powder filled coating, or combination thereof.

E50: The method of E49, wherein obtaining the plurality of briquettescomprises:

-   -   performing sufficient grinding steps and screening steps on ASW        to result in ASW powder; and    -   compressing the ASW powder at a pressure sufficient to form the        plurality of briquettes.

E51: The method of E49 or E50, wherein obtaining the plurality ofbriquettes further comprises adding at least one of: limestone powder,at least one other filler, AC powder, or any combination thereof to theASW powder.

E52: The method of E49, E50, E51, or any combination thereof wherein thepressure sufficient to form the plurality of briquettes ranges from 200psi to 20,000 psi.

E53: The method of E49, E50, E51, E52 or any combination thereof,wherein the ASW comprises:

-   -   asphalt,    -   limestone powder,    -   granules, and    -   impurities.

While several embodiments of the present disclosure have been described,these embodiments are illustrative only, and not restrictive, and thatmany modifications may become apparent to those of ordinary skill in theart. For example, all dimensions discussed herein are provided asexamples only, and are intended to be illustrative and not restrictive.

The invention claimed is:
 1. A roofing shingle comprising: a fiberglassmat; an asphalt shingle waste (ASW) filled coating on the fiberglassmat, wherein the ASW filled coating comprises: asphalt, wherein theasphalt comprises 1% to 40% by weight of waste asphalt, based on a totalweight of the ASW filled coating; and 50% to 70% by weight of a fillermaterial based on the total weight of the ASW filled coating, whereinthe filler material comprises limestone; wherein the ASW filled coatinghaving: A) a penetration point of 15 mm to 45 mm as measured accordingto ASTM D-5; B) a softening point of 190° F. to 250° F. as measuredaccording to ASTM D-3461; and granules on the ASW filled coating.
 2. Theroofing shingle of claim 1, wherein the asphalt comprises 1% to 30% byweight of the waste asphalt, based on the total weight of the ASW filledcoating.
 3. The roofing shingle of claim 1, wherein the asphaltcomprises 5% to 40% by weight of the waste asphalt, based on the totalweight of the ASW filled coating.
 4. The roofing shingle of claim 1,wherein the asphalt comprises 1% to 40% by weight of the waste asphalt,based on a total weight of the asphalt.
 5. The roofing shingle of claim1, wherein the asphalt comprises 5% to 20% by weight of the wasteasphalt, based on a total weight of the asphalt.
 6. The roofing shingleof claim 1, wherein the ASW filled coating having a penetration point of15 mm to 30 mm as measured according to ASTM D-5.
 7. The roofing shingleof claim 1, wherein the ASW filled coating having a softening point of210° F. to 230° F. as measured according to ASTM D-3461.
 8. The roofingshingle of claim 1, wherein the ASW filled coating further comprises anoxidized asphalt.
 9. The roofing shingle of claim 1, wherein the ASWfilled coating further comprises a polymer-modified asphalt.
 10. Aroofing shingle comprising: a fiberglass mat; an asphalt shingle waste(ASW) filled coating on the fiberglass mat, wherein the ASW filledcoating comprises: asphalt, wherein the asphalt comprises 1% to 40% byweight of waste asphalt, based on a total weight of the ASW filledcoating; and 50% to 70% by weight of a filler material based on thetotal weight of the ASW filled coating, wherein the filler materialcomprises limestone; wherein the waste asphalt having thecharacteristics defined by the following process steps: obtaining anASW; and performing sufficient grinding steps and screening steps on theASW to result in an ASW powder; wherein the ASW powder comprises:  thewaste asphalt; and  limestone powder, granules, or impurities; andgranules on the ASW filled coating.
 11. The roofing shingle of claim 10,wherein the ASW powder has an average particle size of 2 microns to 425microns.
 12. The roofing shingle of claim 10, wherein the impuritiescomprise at least one of fiberglass mat, sand, fines, marker paint,sealant, adhesive, tape, plastic debris, paper debris, soil, woods,nails, or any combination thereof.
 13. The roofing shingle of claim 10,wherein the asphalt comprises 1% to 30% by weight of the waste asphalt,based on the total weight of the ASW filled coating.
 14. The roofingshingle of claim 10, wherein the asphalt comprises 5% to 40% by weightof the waste asphalt, based on the total weight of the ASW filledcoating.
 15. The roofing shingle of claim 10, wherein the asphaltcomprises 1% to 40% by weight of the waste asphalt, based on a totalweight of the asphalt.
 16. The roofing shingle of claim 10, wherein theasphalt comprises 5% to 20% by weight of the waste asphalt, based on atotal weight of the asphalt.
 17. The roofing shingle of claim 10,wherein the ASW filled coating having a penetration point of 15 mm to 30mm as measured according to ASTM D-5.
 18. The roofing shingle of claim10, wherein the ASW filled coating having a softening point of 210° F.to 230° F. as measured according to ASTM D-3461.
 19. The roofing shingleof claim 10, wherein the ASW filled coating further comprises anoxidized asphalt.
 20. The roofing shingle of claim 10, wherein the ASWfilled coating further comprises a polymer-modified asphalt.